Sonaré Flutes - SF and PS Models

Powell Sonaré PS-601

We recently had a customer inquire about the model number of his Powell Sonaré flute.  Going back through our serial number files, we discovered that the model he owned was the Sonaré SF-5000, which was actually a very early Sonaré model.  We knew this from the model number and prefix, which have changed over the years as the line itself has...

Powell introduced the Sonaré model flutes at the NFA Convention in 2002.  The history behind the concept is explained by Powell's President, Steven Wasser, in a previous post here on Flute Builder titled The Sonaré (R)evolution (click here to read the post). The very first Sonaré model was the SF-6000, which had a sterling silver body and Y arms.  Two SF models followed -- the SF-5000 and the SF-7000.  The SF-5000 had a nickel silver body with Y arms, and the SF-7000 model had a sterling silver body with pointed arms.  Each of these models had a Powell headjoint which was made at the Powell shop in Massachusetts.  The bodies for these instruments, which had drawn (or extruded) tone holes, were made overseas in China.  In 2006, Powell developed a new patented technology for extruding tone holes.  The new patented process, named "Zinki," was then used to produce the Sonaré bodies at Powell as well.  Powell's President, Steven Wasser, wrote:

During the first few years of Sonaré’s existence we wound up using 4 different scales made by our Chinese partner.  We ultimately standardized on a single scale – the one we though was best – but were still not satisfied.  Since the acoustics of the flute are determined first by the headjoint and secondarily by the scale, we decided to focus our engineering talents on the body.  To make a long story short, in 2006 we came up with a technology we’ve called “Zinki,” that allows us to economically extrude tone holes at Powell with our Modern Powell Scale.  Since then we’ve used Zinki to extrude all Sonaré flute bodies, as well as our Conservatory and Signature flutes.  Even Custom gold flutes with extruded tone holes are done on Zinki

This body production change also marked a change from SF to PS in the model numbers.  Model numbers are engraved on the barrel of the Sonaré flutes, and you will see in the photo below of the PS-601.

There have been several Sonaré flute models over the years, including the 301, 501, 505, 601, 708, and 709, as well as the AF-60 and AF-70 alto flutes.  The 301, 708, and 709 have been discontinued.  Additional options for the PS-705 models will be announced in the next few weeks.  For more information on the Powell Sonaré models, visit https://powellflutes.com/flutes/sonare-flutes.

The Sonaré (R)evolution

Powell Sonaré PS-601 

By Steven A. Wasser

President, Verne Q. Powell Flutes, Inc.

When we decided to co-manufacture a step-up flute in 2002, our conceptualization of Sonaré, with a Chinese body and a Powell headjoint, was ground-breaking.  I vividly recall one of our long-time Powell players coming up to us at the convention that summer.  With her hand on her hip, she demanded to know, “Why Powell is making a flute in China?”  I explained our concept of putting a professional headjoint on an inexpensive flute body, since the headjoint was far and away the most important acoustical component of the flute.  She tried the flute then said, “I’ll take that one.”

We’ve come a long way since we introduced the Sonaré flute in 2002.  For one thing, at last count there were 14 other flute makers who had copied our concept.  For another, the Sonaré flute has evolved.

When we introduced Sonaré we were frankly paranoid about doing something that might jeopardize the Powell image.  Thus, we were extremely careful to distinguish between the flute body made in China, and the headjoint made by Powell in the United States.  The engraving on the headjoint was the normal Powell Signature headjoint engraving, but the Powell name was nowhere to be seen on the body of the flute.  We engraved “Sonaré” on the barrel of the flute.

During the first few years of Sonaré’s existence we wound up using 4 different scales made by our Chinese partner.  We ultimately standardized on a single scale – the one we though was best – but were still not satisfied.  Since the acoustics of the flute are determined first by the headjoint and secondarily by the scale, we decided to focus our engineering talents on the body.  To make a long story short, in 2006 we came up with a technology we’ve called “Zinki,” that allows us to economically extrude tone holes at Powell with our Modern Powell Scale.  Since then we’ve used Zinki to extrude all Sonaré flute bodies, as well as our Conservatory and Signature flutes.  Even Custom gold flutes with extruded tone holes are done on Zinki.  (If you’re curious about the technology you can look up U.S. patent #7,420,109.  It describes our approach for putting a big ball through a small hole.)

By using flute bodies made at Powell with the Modern Powell Scale, we felt we had made a large leap in quality.  At that point we decided Sonaré could become a Powell flute.  Sonaré then became a model designation, just like Signature or Conservatory.

However, we aren’t done making improvements.  Starting in spring, 2015, the Sonaré flutes being assembled for us in China will be utilizing cups that are the same size and shape as the Powell flute cups used for Conservatory and Signature flutes. 

One final point.  Because we make the body and headjoint of the flute at our Maynard workshop, and because we do the final finishing at Powell, we have an instrument where more than 50% of the content is U.S. content and where final finishing takes place in the USA.  Thus, our Powell Sonaré flutes qualify as “Assembled in USA.”  To the best of our knowledge no other flute in this category qualifies for that country of origin labeling.

Signature Spotlight

Thinking about purchasing a Powell flute but afraid that it might not meet your budget?  We understand that "one size does not fit all" when it comes to flute prices -- and options!  Also, hand craftsmanship is not limited to Powell Custom models, either, because all of our flutes are handmade!  So, if you are looking for handmade flute with an economical price tag and the options to accommodate your preferences as a player, the Signature is an excellent choice.

The Powell Signature flute offers hand craftsmanship and the "Powell Sound" at an affordable cost.  The Signature's body and headjoint are both sterling silver, and the Signature headjoint was created specifically to accompany the Signature flute.  The headjoint makers here in the shop who cut the styles offered on our Custom and Conservatory flutes also cut Signature headjoints.  The Signature's drawn tone holes are formed using Powell's patented Zinki technology, and the pinned mechanism is completely built by hand.  Signature options include B foot or C foot, inline or offset G, C# trill, split-E (on offset G models), and a 14k riser.

In addition to the Signature flute, there is also a Signature piccolo!  The Signature piccolo has been described as a responsive, professional instrument with evenness throughout the scale and a consistent, sweet sound.  As one of two Powell piccolo models, Signature piccolos are crafted by the same flute makers who build the Custom piccolos.  The Signature piccolo body is made from grenadilla wood, and the mechanism is sterling silver.  Signature piccolos also have the option of a split-E and the choice of a Classic or Wave style headjoint.

For more information on Signature flutes and piccolos, click here to visit the Signature flute page on the Powell website and here for the Signature piccolo page.

Zinki: Powell’s Tone Hole Extrusion Process

By Steven Wasser - President, Verne Q. Powell Flutes

What’s in a name?  In this case a lot, but the name itself is something we just made up because it sounded like fun. 

Zinki is the name we’ve given to Powell’s patented process for extruding tone holes on one of our CNC machining centers.  

The "Zinki" CNC Machine

The traditional process for extruding tone holes generally involves at least 3 separate steps, each one involving a different setup on a different machine, as follows:

1.      Make a small hole in the tube where the tone hole is going to be.  Usually this involves drilling or punching an egg-shaped hole.

2.      Load solid pulling balls into pockets in an arbor, then slide the flute tube over the arbor and place on a machine.  Position dies over each tone hole.  Connect a spinning shaft to the pulling ball and pull up through the die, pulling flute tubing with it to form the tone hole.

Traditional pulling ball.

3.      Remove the tube from the pulling arbor and place it on another machine.  Face each tone hole level with a cutting tool, then use a special tool to roll over the tone hole edge to (a) eliminate the sharp edge and (b) reinforce the tone hole.  

The process normally takes 30-45 minutes and uses both extrusion - a brute force technique - and spinning to form the tone holes.  The force required has a tendency to pull metal from the tube into small ripples alongside the tone holes.  And each time a flute tube goes from one setup to another, accuracy is lost.

Powell’s Zinki technology delivers the pulling ball from the outside of the flute tube, rather than pre-loading it on an arbor inside the flute tube.  In order to do this Powell needed to figure out how to put a big ball through a small hole.  Instead of a single large ball, the Zinki pulling ball is actually a series of small balls which can expand and contract. The details can be viewed at U.S. patent #7,420,109B2.

Close-up on Zinki pulling ball.

With Zinki the balance between extrusion and spinning shifts to spinning.  The result is a highly accurate tone hole with little if any rippling on the tube.  The last step in Zinki is to “kiss” the top of the tone hole with a diamond facing tool to make sure that it is level.  And all this takes place in a fraction of the time for traditional tone hole extrusion.

Powell Conservatory (Drawn Tone Holes)

Close-up on drawn tone holes.  Red arrow points to the rolled edge.