Inside Sennheiser’s Elite Headphone Manufacturing Facility
Tucked away in Tullamore, County Offaly, Ireland, Sennheiser’s factory is producing some of the world’s most revered headphones. The facility, now part of Sonova Holding AG since 2021, has been manufacturing transducers since 1991 and has since expanded to assemble and package some of Sennheiser’s most prestigious models.
A Brief History of Sennheiser’s Innovation
Fritz Sennheiser founded the company in 1945 in a Hanover farmhouse. The pivotal moment came in 1968 with the introduction of the HD 414, featuring open-back design. Since then, Sennheiser has continued to push boundaries with models like the HD 600, HD 650, and the flagship HD 800.
The Manufacturing Process
The production line is a blend of automation and human expertise. Pat Fulton, the plant manager with over 30 years of experience, guides.
- Transducer Creation: The process begins with selecting materials for the transducer, where a 0.03mm wire is bonded to the membrane.
- Testing and Quality Control: Each component undergoes rigorous testing to ensure optimal performance.
- Assembly: Skilled technicians assemble the headphones, with models like the 800 Series requiring specialized training.
- Validation: Finished headphones are placed in anechoic chambers for frequency sweeps to verify alignment and performance.
Assembling the Sennheiser HD 660S2
Visitors participate in assembling the HD 660S2, a process that involves attaching mesh grilles, clipping in foam cushions, and connecting detachable cables. The result is a refined listening experience with clear, detailed sound reproduction.
The HE 1 Electrostatic System: A Technological Marvel
The HE 1 is a masterpiece of engineering, featuring:
- A block of Italian Carrara marble for its aesthetic and vibration-damping properties
- Eight ESS Sabre ES9018 digital-to-analog converters
- Gold-vaporized ceramic electrodes to eliminate distortion
- A vacuum tube preamplifier for summit-fi technicalities
The HE 1 offers an unparalleled listening experience, with reproduction of 8 Hz to over 100 kHz and distortion less than 0.01% at 1 kHz.
Listening Experience
In an acoustically treated room, the HE 1 is showcased. Tracks like Massive Attack’s “Angel” and Fleetwood Mac’s “The Chain” demonstrate its capability to deliver nuanced, immersive sound. The experience is both captivating and revealing, showcasing the headphones’ ability to faithfully reproduce complex audio.
Parallels Between Headphones and Whiskey
The tour concludes with a visit to the Tullamore D.E.W. distillery, highlighting parallels between crafting headphones and whiskey. Both involve meticulous attention to detail, layering components to achieve a harmonious final product. Just as a fine whiskey requires patience and expertise, so too does the creation of exceptional headphones.
The journey through Sennheiser’s factory underscores the blend of tradition, innovation, and quality control that defines their products. For audiophiles and casual listeners alike, the experience offers a glimpse into the making of extraordinary sound.
