WHO COULD YOU BECOME?
A LIFE STUDY OF TWO AUDIO PROFESSIONS
Brass Instruments are an important part of a wide variety of musical genres. From classical orchestra and chamber music, to big band jazz or church trombone choirs. When we sit in a concert hall, captivated by the encompassing sound, we tend to forget the craftsmanship that goes into every instrument. In this blog I want to take a deeper look at the profession of brass instrument making, repair and restoration. How do you become an instrument maker? What skills and responsibilities does this profession entail? And what are the challenges of following a centuries-old tradition?
Brief Historical Background
Brass Instruments have their origins in ancient times. Prototypes were seashells or
hollow animal horns, often used as means to signal over distance due to their high
level of amplification. The oldest crafted brass instrument was a natural trumpet
called Scheneb, found in the tomb of pharaoh Tutanchamun. So it can be assumed
that the tradition of brass instrument making dates back to the Egyptians. Over the
following centuries these rather primitive ancestors evolved into the sophisticated
instruments we know today. The development of the instruments themselves and the
craft behind them were always strongly influenced by general advances in
metalworking and in return effected the musical expression of the times.
The instruments of the baroque period for example only allowed for the playing of
notes in the harmonic series (with the exception of the trombone). Only after the invention of valves around 1810 could brass instruments be used to play chromatically. So the craft of brass instrument building was never just a service to the music of the times. It can be seen as an integral part of the creative process too.
The Role of a Brass Instrument Maker
As instrument maker, Norbert Walsch explained to me, the most important and joyful
part of his practice is the interaction with players. For that reason his workshop is
open to the public so that anybody can observe and overview what exactly is
happening to their beloved instrument when it gets 'under the knife'. Apart from
manufacturing of new instruments his services include repair and overhaul,
reupholstery, varnishing, gilding, plating, professional cleaning and maintenance,
individual modifications and restoration of old instruments. Some of his customers
are professional players to whom their livelihood depends on their instrument. So an
attention to detail is of the greatest importance.
Required Skills & Training
The road to becoming a brass instrument maker in Germany usually goes through an apprenticeship with an established company or through specialized schools. The skillset acquired by the end of the education typically includes the following:
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practical training: including mechanical parts and bell construction, material techniques, surface treatments, mechanical adjustments and repair methods
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trade-related education: instrument making theory, technical drawing, mathematics and physics & acoustics
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general education & musical training (typically not part of an apprenticeship): including music history and theory, music lessons and/or ensemble rehearsals
But as everyone self-employed knows, a purely trade-related skillset will only get you so far. A good customer contact is almost as important as the quality of your work. Most of Walsch's customers are regulars that have gained a trust in his expertise and work ethic. So if they need an emergency repair done before an important gig, they know that their instrument will be back and playable in time. As in all instrument making fields conventions are the main platform for client acquisition and networking. They are an opportunity to present your work to the broader, interested public.
The Building Process
In his book 'The Modern Trombone' Stuart Dempster states: “The trombone is not an instrument in the usual sense, since it has no reed to make sound; rather it is a resonator of whatever sound is introduced at the mouthpiece.” This is true for all instruments in the brass family. Two main factors effect the sound of a brass instrument while resonated by the player's lips: the attributes of the material and the shape of the instrument.
Material & Shape
Brass instruments typically consist of a mixture of copper, zinc and nickel-silver alloys for inlays. The proportion of the materials have a significant influence on the sound of the instrument. Increasing the copper content makes for a darker, warmer and heavier sound while a higher zinc content creates a brighter, thinner and lighter sound. Apart from the composition of the material, thickness and hardness are important factors too. There are different processes for
softening and hardening the material.With the thickness the weight and projection of
the sound increases.
The shapes of the instrument's tubing, bell and mouthpiece all significantly influence
the sound. The length of the tubing defines the fundamental pitch. As the main
resonating part the bell determines the amplification and clarity of the produced sound,
while the shape of the mouthpiece effects playability and tone.
All of these design choices work together to create the unique characteristic of the
instrument. The instrument maker has to strike the right balance between these factors
to achieve the desired sound. Therefore an in-depth knowledge of the materials that
are used, the steps to process it and the acoustic effects is essential. Every player's lips and the resulting buzz are different. An experienced instrument maker can also help the player find the instrument that fits best to their personal style of playing.
Tradition vs. Innovation
The field seems to be chronically understaffed. A lot of workshops are hiring and schools have problems filling their classes every year. Like a lot of traditional professions the craft of instrument making faces a number of challenges in the modern world.
At Norbert Walsch's workshop everything is hand-made – no computers allowed. For a lot of brass instrument makers (and players) the 'hand-made' tag is important. It means that every step of the process has a consistent quality control but even more importantly it means that the finished instrument is completely unique. It has a soul. The competition from Asian manufacturers is fierce. These companies produce in production lines and use CNC machining to save labor costs. As a result the instruments are significantly cheaper than a local hand-made model. They quickly took over the amateur market where the player's expectation can be met easier making a lot of traditional manufacturers orient themselves towards professional players only. But the making of high-end instruments needs highly experiences workers which are increasingly harder to find.
The production of brass instruments raises environmental concern. Zinc reserves are
expected to last roughly for another 15 years with a relatively low recycling rate of
around 30 %. UK manufacturer pBone produces plastic alternatives to brass
instruments with 10% of the carbon used in making a brass instrument. While the sound
of plastic still doesn't compare to brass, they have become a common choice -
especially for music schools – due to their low price, lighter weight and longer durability.
Traditional manufacturers are coming up with new solutions as-well. The Saxon
company Werner Chr. Schmidt developed a red trumpet that is free of nickel and lead and
compares well to conventional instruments.
With a steady interest in high quality instruments, good customer service and a growing trend of the restoration of old instruments not all hope is lost for the brass instrument industry. But the field has to come up with effective and sustainable solutions for the sourcing of materials, waste management and recycling.
The profession of brass instrument making is fascinating to me because of its blend of craftsmanship, design and acoustics. It plays a crucial role in the development of the musical landscape as a whole. As a trombonist myself I find it interesting to retrace and understand the necessary part of the creative process that comes before I pick up my instrument to play.