Pharmaboy
Headphoneus Supremus
Hi, yes, the customer has all the right to ask for a replacement if there is a white dot, and we will replace.
But it is more complicated that that.
Usually milled aluminium is polished and sandblasted.
CNC milling means that a drill carves out the entire shape thus leaving behind a trail. Polishing evens out this trails(marks) left behind by the drill head. The sandblasting creates an even grainy surface (such as mac laptops). Final effect is a smooth textured surface.
The anodizing means basically oxidizing the surface. Anodizing is not adding an extra layer but corroding the top surface of aluminium thus creating a barrier. In this process you can add pigment which enters this corrosion crevasses.
But we didn't do this. Because (to the dismay of my team) I usually choose the hard way in order to create something unique:
What we did was to work like crazy until we go an nice even milling tool path effect and then directly anodize it. This means that there is not polishing or sandblasting to cover up any imperfection caused by milling. This process causes causes a lot of extra cost and headache due to the very high scrap rate.
Bellow a closeup of this type of milling texture on a prototype I am working on for a new IEM. This texture is made with ball head milling head. This picture is from early 2018 and i still didn;t release this model with this texture just because we still weren't able to stabilize this texture in mass production. (We will release it first without texture and keep working on this texture for future releases). We are fanatic about making something special. Not choosing the easy path. We could have simply made a casting tooling like everyone else and cast all the Empyrean aluminium parts and then paint them and you would have a frame with same surface effect like all other aluminium headphones frames.
As you can see in the image above the surface consists of "hills and valleys". It is very difficult to create an even anodizing color effect across the entire surface when your surface is textured like this.
White dot means the anodizing didn't fully take effect on on of those countless surfaces.
Bellow is closeup of Empyrean texture which I am super happy to have achieved after great difficulties.
It's necessary to understand that this frames as a sort of craftsman's work that is not at all like serialized mass production. It's like a carving with a CNC machine. Even if there is a programming in the machine, the outcome will not be always identical at microscopic level and the the anodizing will just reveal that. And due to the extremely high detail and the countless facets created by the mill on the surface of the aluminium it is very very hard to achieve 100% even coverage.
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This post--and this technical information it conveys--are amazing. That closeup of the Empyrean shows detail I didn't even see IRL.