Background

                                                   Background on Piano Manufacturing

Audi Design- 2009

The first pianoforte (the full title for the modern piano) was created by an Italian named Bartolomeo Cristofori around 1700. Although the piano was revolutionary in its uniqueness of sound and control, it was supposedly a redesigned version of the harpsichord and clavichord. Pianos are designed by specialized engineers called scale engineers. New designs are still being created today, such as the Audi design in 2009. With this in mind, each factory has a different way of making their pianos unique, including their use of materials and method of production.

Pianos require different types of wood for various parts—each wood containing special qualities that make them the best for multiple purposes. The outer rim is composed of a hardwood that has strength and elasticity, such as maple or beech; however, Bösendorfer uses spruce wood for both the outer rim and soundboard, which is uncommon and gives the Bösendorfer an unusual sound. Cast iron or cast steel is used for the main frame, while the strings are usually composed of high tensile wire or high carbon steel. The bass strings are additionally coated with copper since they will be burdened with more tension and require additional mass. The soundboard, as mentioned earlier, is made of spruce for its strength and minimal acoustic disturbance.  The keys of the instrument used to be made of ebony and ivory, but are now composed of spruce in most pianos. The hammers attached to the keys are made with wool felt and most of the additional parts are made of hardwood, again for its strength. Each material serves a different purpose, but it is not uncommon for even the high-quality piano industries to show discrepancies among the materials they use. 

Cast Iron Frame

Hammers

Strings

Piano manufacturers have tried to incorporate some of the latest technology into their process, while still keeping some of their traditional craftsmanship by hand. The new computer-controlled machines add exactness to the pianos that increase the quality and ease of the procedure; however, a lot of the precision work is still done by hand. More than 10,000 steps go into making a grand piano, according to the Bösendorfer factory. The rim of the case is created by the bending and gluing of long-fiber woods; however, the Bösendorfer factory makes many small cuts in the spruce wood to bend it into shape. Next, the cabinet is sanded, stained, wood-bleached, sealed, and glazed with repetitions or other minute steps involved. The pinblock is sawn or cut, and then holes are drilled into it for the tuning pins, nosebolts, etc. The cast iron is made in a piano foundry, where molten metal is poured into a mold. The soundboard is made similar to the rim—it is cut into strips, glued together, and then curved. The strings are measured using scale sticks and then wound around the tuning pins. Piano keys are cut and covered with black and white plastic. All the other additional necessities of the piano, such as the pedals, key cover, and music rack are put into place, completing the building process.

Pinblock

The uniqueness of sound among each different brand of piano is due to the different materials and methods used by the manufacturer. This background report gives only a small and general insight into what goes into creating a grand piano. Throughout my visits to each of the factories, I hope to expand this knowledge and learn the individual methods specific to the various factories.