To understand the manufacturing is to understand the old ways of manufacturing 100 years ago. Master full sized copies, called hubs, were hand carved into unhardened tool steel using a hammers and intricate chisels by hub cutters. The Hub was then hardened and then placed on top of anther piece of tool steel in a massive drop hammer press. The resulting impression became the master die.
The die and its fitting trim tools were them set up in presses and raw metal stock(brass, silver, gold) was run through the presses on the factory floors. The structural integrity of the pieces being squeezed in a press with up to 100 tons of pressure makes for a very durable piece that is superior to a casting process.
This pre CNC method of manufacturing required expert craftsman at every step of the way and fortunately we have been able to track down the last of the Old Breed who know how to this in Providence, Rhode Island and Attleboro, Massachusetts.
