Making the Body

Let's focus on the making of the rim first.

The photographs below show wood veneers that are glued together lengthwise to form a layer of the piano's rim. These layers are joined together to make a single long board by being glued and laminated. The number of laminations of these layers varies depending on the model, but is usually from 6 to 10.

Once the long laminated wood board is complete, it is placed in a press that uses high-frequency energy to heat the wood, and hydraulic pressure to press the board into a large mold that has the distinctive shape of the piano case. Resin-impregnated paper is then glued to the outside of the rim to provide a receptive surface for later finishing process.

The inner rim that forms a frame on the inside of the rim is made in a similar fashion.

Next, the inner rim that supports the curved contour of the outer rim is assembled with straight beams to form the structural framework of the piano. The beams are notched into the inner rim using traditional dovetail joints, and the surface is planed flat.

The soundboard will later rest on the inner rim, which is milled to accommodate it. The top of the soundboard has a crown (a slight dome) that arches upward toward the strings, and the top surface of the inner rim is cut to match its slope angle. In addition, a number of reinforcing ribs are glued to the underside of the soundboard, and slots are milled into the inner rim where these ribs will fit. Finally, the outer rim, which has been seasoned at a specific temperature and humidity, is joined with the inner rim into a single unit using high-frequency induction heating.

A robotic system is used for the finishing process. First, an undercoat is sprayed on and kept warm so that it dries and hardens quickly. The final topcoat is applied in the form of an extremely fine mist, followed by a polishing process that results in an attractive, beautifully finished surface.