DESIGN PHILOSOPHY
The difference with our methods
We decided to take the manufacturing process of carbon fiber violins to the next level. Other makers of carbon fiber violins use one of two production methods.
- Wet Layup Vacuum Bagging - a common boat builder’s technique.
- Vacuum Bag Infusion - a more sophisticated method used in boat building and small airplane production.
The “Gayford-Carbon Strad” exceeds these methods by using the same techniques used by the aerospace industry and Formula One race cars. This method uses an Autoclave pressure chamber and high performance pre-preg carbon fiber cloth. The Autoclave subjects the violin plates to high temperatures and a clamping mold pressure of 8000 lbs. Only pre-preg carbon fiber gives a uniform resin to fiber ratio that other methods cannot achieve.
This is a very expensive process which yield’s parts with far superior acoustical properties.
We performed many experiments on dozens of violin plates using the three production methods described above. We conducted a tonal ring test on each of the plates and the results were very different with each method. Tapping the wet layup & infusion violin plates used by other manufacturers sounded like tapping on a drinking glass. Tapping on our Autoclaved violin plates yielded results that sounded like tapping on crystal glass. Obviously, the results prove our production methods are worth the extra effort.
A Simple Explanation of our Process
The carbon fiber cloth comes in a frozen state with factory spec quantities of epoxy resin and catalyst already impregnated into the carbon cloth. The carbon cloth is placed in high temperature molds and vacuum bagged to full atmospheric pressure. This mold is then placed inside an Autoclave which delivers 5.5 tonnes of pressure (5 times atmospheric pressure) to form the 23 parts of the violin. Electric elements heat the molds up to high temperature to complete the curing process. 24 hours later after the pressure drops and the temperature returns to normal the parts are removed from the chamber and de-molded for assembly.
Testing the audio performance of the various finished pre-production violins at Fairmeadow Studio with master violinist Trevor Dick of “Flying Bow Music Ministries”
In striving to achieve nothing but the best in sound reproduction we went through more than 30 prototypes before perfecting our final production design.
About Prepreg Carbon Fiber Fabric
"Prepreg" is the common term for carbon fiber reinforcing fabric which has been pre-impregnated with epoxy resin including the proper curing agent. As a result, the prepreg is ready to lay into a mold without the addition of any more resin. In order for the laminate to cure, it is necessary to use a combination of pressure and heat in an Autoclave.
Advantages of Prepregs
In a hand layup or vacuum infusion process, it is difficult to achieve 50% resin content. Typical hand laminates and vacuum infusion, end up with a significant amount of excess resin. Excess resin increases brittleness and reduces the overall properties of the final product. On the other hand, most prepreg fabric contains around 35% resin. This is ideal for maximum cured properties and generally impossible to achieve in any other method. There will be neither resin-rich areas nor dry spots. The final result is the strongest, most uniform and consistent product possible.
Assembled like a traditional wood violin.
Our violins are comprised of 23 individual, autoclaved, carbon fiber parts. They are then assembled by hand in precision, mounting fixtures. Any part can be replaced just like the parts on a wooden violin. Other manufacturers of carbon fiber violins generally create a one piece body that incorporate the side ribs, neck, and peg box that can't be separated. Repairs are next to impossible.