Tiffany Haney
Handpans are widely known and sought-after instruments, with prices ranging from $1,500 to $3,000. The process of making a handpan involves several steps, including metal forming, heat treating, shaping, and tuning. Makers use different methods for metal forming, such as hydroforming, deep drawing, and hand hammering, with each method producing unique results. Heat treating involves various techniques like torches, kilns, ovens, or furnaces, and it is crucial for achieving the desired timbre, stability, and sustain of the instrument. Shaping is a critical step where makers use different tools and hammers to create the distinctive dimples and borders of the handpan. The tuning process is considered one of the most challenging skills to master, as it requires an understanding of metallurgy and the ability to make sonic adjustments.
| Characteristics | Values |
|---|---|
| Metal Forming | Deep drawing, hydroforming, hand hammering, nitrating |
| Heat Treating | Furnaces, ovens, kilns, torches |
| Shaping | Hammers |
| Tuning | Sonic adjustments |
| Cost | $1,500 to $3,000 USD |
| Waiting Time | 1-3 years |
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What You'll Learn
Metal forming
The most basic method is to hammer the metal plate by hand, which can take thousands of hammer blows to achieve the desired shape. This method, though labour-intensive, is preferred by some makers for the unique sound it produces. Another method, developed by Pantheon Steel, involves rolling the shell, where a machine rolls around the metal sheet to form it into a dome shape. Alternatively, a pneumatic press can be used to shape the metal, which is less labour-intensive than the previous methods.
One of the most innovative methods of forming shells is by using water under pressure. This hydroforming technique was first used by Sunpan to make stainless steel shells for their handpans. This method was made public by renowned player and maker Colin Foulke in 2015.
After the shell has been formed, the next critical step is heat treating, which increases the stability and sustain of the instrument.
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Heat treating
The treatment times, temperatures, and other variables differ from maker to maker. This means that some nitrided handpans are more rust-resistant than others. If you live in a humid climate or near the ocean, it is a good idea to oil your handpan at least once per month. If you live in a dry climate, you can go for months without needing to re-oil.
To prevent rust, it is important to keep your handpan clean and dry. Store it out of its case, and keep the handpan case clean and dry too. If rust does appear, don't panic! Unless the handpan is left outside in a humid environment for many years, rust will only be a cosmetic concern. You can remove rust by wiping down the handpan with a soft, clean, dry cloth, preferably microfibre. Alcohol is optional—use a generous amount on a cloth and thoroughly clean all surfaces, inside and out. If you have a stubborn rust spot, you can dampen the green side of the scourer with a tiny splash of water and brush gently over the rust. However, be careful, as this may also remove any finish that the handpan has.
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Shaping
Sinking or Shell-forming:
The first step in shaping a handpan is transforming a flat steel sheet into a bowl or dome shape, commonly known as "sinking." This can be achieved through various methods, including hammering, deep drawing, hydroforming, or spinning. Each method has its pros and cons, and the choice depends on the maker's preference and resources.
Border and Interstitial Work:
The shape of the handpan's border, whether sharp and thin or wider and softer, significantly impacts the sonic character of each note. This phase involves intricate balance and control, as the metal between the notes (interstitial work) is hammered and shaped. The border and interstitial work together determine the character of each handpan and how it will be tuned and played.
Heat-treating:
After the initial shaping, the handpan shell undergoes a heat-treating process called nitriding or nitrating. This step is crucial for increasing the stability and sustain of the instrument. Metal tends to have a "memory," and heating and cooling at specific temperatures help stabilize the newly shaped architecture, preventing the metal from returning to its original shape.
Fine-tuning the Shape:
Following the heat-treating process, fine adjustments are made to the handpan's shape. This involves pre-stressing the tone fields to compress the metal around the notes and ensure stability. The depth, diameter, and slope of the shell influence the thickness of the steel, resonance, and overall shaping and tuning process. Makers often use software to decipher the notes that ring when each axis is played, allowing them to subtly shape the metal to achieve the correct pitch for each axis.
The shaping process is a delicate and intricate part of handpan creation, requiring a deep understanding of the metal's properties and the desired sonic outcome. It forms the foundation for the subsequent tuning process, where the handpan's unique sound is brought to life.
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Tuning
The tuning process for a handpan can be considered to start in the shaping stages. The idea is that tuning is shaping, and shaping is tuning. Preparing the metal in the optimal way and creating the right note borders are crucial before tuning begins. The depth and curvature of each dimple will have slight variances, adding to the unique character of each dimple. Using hammers instead of a pneumatic press for the shaping process can provide a more "hands-on" feel to the handpan.
The selection of the right material is critical, and it requires an understanding of steel kind and grade, chemistry, and thickness. There are thousands of steel grades to choose from, and the wide industry standards and tolerance ranges may not be well-suited for reproducing tuned steel instruments. Nitriding is an essential building block in the tuning process, as it creates a “white layer” that acts as a barrier to rust.
For the actual tuning process, there are dedicated handpan tuning apps that offer preset scales and visual aids to guide you. These apps can be very helpful in achieving the correct tuning for your handpan. It is important to note that handpans can go out of tune over time, and the time it takes for this to happen depends on the manufacturer and processing method. High-quality handpans can remain stable for two to five years, while cheaper options may go out of tune in a few months.
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Glueing
Gluing
The process of crafting a handpan involves a lot of hard work and patience. The final steps include gluing the handpan together. The two halves of the handpan are carefully adhered to using specialised glues. The chosen adhesive needs to be strong, durable, and resistant to vibrations generated during playing. Builders often prefer epoxies specifically formulated for metal bonding, ensuring a long-lasting and secure connection.
The top shell (the one that has been adjusted) is glued to the bottom shell. The bottom shell is made by following the same steps and punching a hole in it, which will become the opening in the bottom of the handpan. After the glue has cured for the appropriate amount of time, the rim (flange) of the two shells is trimmed and polished to a smooth finish. The handpan is then cleaned and a wax protectant is added to protect the shell from moisture and other corrosives.
It is important to note that while cleaning the handpan, acetone should be avoided as it can degrade the finish and the glue holding the handpan together.
As the glue cures, the handpan is tuned multiple times to ensure stability and is fine-tuned a final time before it is ready for use. This process involves accessing the interior of the handpan through the soundhole to make precise adjustments to the note fields using specialised tools.
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Frequently asked questions
The steps to process a hand pan are metal forming, heat treating, shaping, and tuning.
The first step in the hand pan-making process is metal forming and the nitrating process.
A special heat-treating process called nitrating is the critical process following shell-forming.
The different methods to form shells are hydroforming, deep drawing, and hand hammering.
The hand pan tuning process is considered to be the most difficult skill to master.
