Mechanical Music Movement

The arranger converts a musical score—whether from an existing piece or a bespoke composition—into a melody suitable for the music box movement. This requires the talent and ear of a composer, as well as mastery of both technology and music. Many hours are invested in transforming multiple notes into melodic harmony.

Tiny holes are drilled into the cylinder according to the arranger’s composition. Since some cylinders can contain up to three different melodies, this is a highly complex process that requires the utmost precision.

Using a pinning lathe, an extremely fine steel wire is inserted—much like threading a needle—into each of the holes drilled into the cylinder. The wire is then cut, leaving a pin in place that will pluck a tooth on the comb as the cylinder rotates. The number of pins on a cylinder for a movement using a 72-note clavier, for instance, can easily exceed 1,200.

Each cylinder undergoes a meticulous visual inspection. Using a high-power inspection microscope, the artisan carefully checks that all pins are in perfect condition, absolutely straight, and that none are missing. If necessary, a new pin is manually inserted using a special tool called a “pusher”.

The cylinder’s inner wall is lined with resin to seal each pinhole and ensure all pins remain firmly in place; this process also has the effect of improving sound quality. The composition of this resin is one of Manufacture Reuge’s best-kept secrets.

Once all the pins are fixed in place, checked, and gummed, they are trimmed to the same height.

Stamping, also called pressing, is a manufacturing process used to convert a flat metal blank into a final shape. The blank is placed in the stamping press, where a tool and die come together to form the final shape. Punching, blanking, bending, coining, embossing, and flanging are all stamping techniques. Comb, speed regulators, and barrels are produced using techniques for cutting or stamping steel or brass strips.

Manufacture Reuge combs are machined with a computer numerical control (CNC) milling machine to remove excess material and give the blade their initial shape before they are actually cut out.

A milling cutter is used to create the individual blade on the comb. Each comb is custom-made for the specific melodies to be played by the movement.

The comb is heated to 800°C, then quenched in a lukewarm oil bath. This ensures the blade have the optimal hardness, neither too brittle nor too elastic, which is crucial for producing the proper sound. It also helps protect the blade from deformation.

A Zamak alloy, made of zinc, aluminum, magnesium, and copper, is poured beneath selected teeth. A saw is then used to separate the Zamak mass, forming the individual blade that will produce the lower notes.

During the tuning process, a machine makes each blade resonate and compares its vibration frequency to the desired note. A grinding wheel is then used to finely adjust each tooth, ensuring it produces the correct pitch.

Damping feathers, are meticulously glued beneath the blades of the bass notes. This process ensures a cleaner sound by preventing unwanted vibrations, particularly those with an overly metallic resonance.

Each musical movement is meticulously assembled by hand. The artisan carefully fixes the cylinder, barrel, speed regulator, trigger, and melody indicator onto the bedplate. Through precise and deliberate gestures, the artisan brings the movement to life.

Fixing the comb is the most delicate step in the final assembly of a music box. The artisan aligns the comb precisely in relation to the cylinder, ensuring an exact distance from the pins. Achieving the perfect Manufacture Reuge sound requires experience, expertise, and a keen musical ear.

After a final inspection, the movement is placed into its case. With a sense of satisfaction, the artisan closes the lid, knowing they have created an exceptional object of the rarest kind—one capable of enchanting and evoking the deepest emotions.