1. Designing and Prototyping:
- Designers create blueprints and specifications based on the desired characteristics of the saxophone.
- Prototypes are made using computer-aided design (CAD) software and rapid prototyping techniques.
2. Material Selection:
- The saxophone is primarily made of brass, an alloy of copper and zinc.
- Different types of brass can be used to achieve specific tonal qualities.
3. Forming the Body:
- Sheet brass is formed into the desired shape using specialized machines.
- This process involves cutting, rolling, and hammering the brass to create the body components.
4. Soldering and Assembly:
- The formed parts are soldered together to assemble the body of the saxophone.
- This requires precision craftsmanship to ensure proper alignment and airtightness.
5. Machining and Finishing:
- The body is machined to create the keyholes and other precise features.
- The keys and their mechanisms are also machined and fitted into place.
6. Keywork and Mechanism:
- Keys and their connecting rods, also known as keywork, are installed.
- This involves intricate adjustments to ensure proper action, key spacing, and precise playability.
7. Lacquer and Plating:
- The saxophone is finished with a layer of lacquer to protect the metal from corrosion.
- In some cases, the saxophone may be plated with metals like gold, silver, or nickel to enhance its appearance.
8. Quality Control:
- Thorough testing is conducted to ensure the saxophone meets quality standards.
- This includes intonation testing, key action, and overall sound evaluation.
9. Final Assembly and Adjustments:
- Final checks and adjustments are made to the instrument's mechanism and regulation.
- This includes adjusting spring tensions, key heights, and pad alignment to achieve optimal performance.
10. Packaging and Distribution:
- The finished saxophone is carefully packaged to protect it during shipping.
- It is then distributed to retailers or music stores for sale to professional and amateur musicians.
It's important to note that making a saxophone is a highly specialized craft, and the steps mentioned above are simplified and generalized. The actual process can vary depending on the specific manufacturing practices of different saxophone makers.