Regarding the drops - they are definitely tough to run, and for all of our sanity we have always had every sale be final - the butterfly effect of headphones going up and down off the page with future ZMF owners wanting to change sets as the available sets change would just be too much for us to handle. I think ultimately this leads to more happy ZMF owners, vs feeling like you always missed something and someone else got something that you weren't given the same opportunity to get. There's never going to be a perfect way, but that's also why we're working on the custom shop for the future.
A few folks commented on our profit margins are. It’s way more complex than “this part costs X and they charge Y.” When it was just me (or me + two), things were simpler; today, small‑batch U.S. manufacturing is a web of moving parts that all have to stay in balance. Here’s what that looks like at ZMF:
1. Two buildings, one mission
We utilize ~18 k sq ft of CNC-wood‑shop and assembly space between two buildings so we can control humidity, dust, and vibration down to ±0.001 in. Taxes, insurance, and upkeep live in every headphone’s price tag.
2. Million‑dollar machines, handmade results
CNC routers, 5‑axis mills, lasers, and in‑house wood stabilization run into seven figures, before maintenance, software, and power. Profits also fund R&D rigs, printers, and the inevitable “fail, learn, rebuild” cycle. After running ZMF since it was just me, I’ve learned the hard way about inventory management and that time is money. I’d rather just focus on building and designing headphones honestly.
3. People over payrolls
Our crew are career craftspeople, not temps: living wages, health care, 401(k) + profit share, paid training, bonuses. Skill shows up in sound quality—and on the overhead line.
4. Warranty and Parts
When we promise a lifetime warranty on sonic performance, we’re also promising to keep spare parts, drivers, earpads and jigs on the shelf long after a model is produced. Setting aside reserve stock, and the cash to service it, is part of every sale—think of it as prepaid support you might never need but we
must be ready to honor. We also run a business that is semi-custom – meaning there’s tons of parts. We also have a different cup design for every model. There’s inventory everywhere and it isn’t “lean” in the proper Toyota way, I know you KanBan nerds know what I’m talking about. We have to keep this inventory for the reasons above, and because it allows us to make cool stuff.
5. The unglamorous bits
UL‑rated power, safety equipment, cybersecurity, RoHS/REACH testing, liability coverage, repairing leaking roofs (yes we had that happen this year) etc. All of these need to be in place for the business to operate.
Why margins matter
If we price too low, we can’t invest in people, process or innovation, and the brand withers. If we price too high, we alienate the very enthusiasts who got us here. The “margin” is the narrow lane where we fund tomorrow’s headphones, keep today’s team thriving, and still deliver genuine value to the community.
I made the decision a while back not to sell to distributors, and even our dealers are constantly complaining about our smaller than usual margin. I have not waivered on this and if it doesn’t work for them I don’t bend. Why? Because it means that you as the consumer can get a hand-crafted wood headphone made on world class equipment, with patented acoustic system (that also cost a lot of money to prove worthy of a patent) that make headphones which apparently are good enough to be copied and targeted by other businesses for a price that is competitive with the rest of the high end audio world. I know they cost a lot – but if we went the way of much of this industry (the not 1-5 guy shops) with distributor pricing, forget about the tariff issues, a Caldera would cost a lot more and I’d feel like a jerk selling it. Like you guys am an enthusiast and I try to view everything from that lens – while crunching numbers constantly to make sure everything makes sense and is fair to our staff, and the people buying our stuff.
So yeah, running a niche, handcrafted audio company is more than “number A vs. number B.”
Thanks for asking—and for keeping us honest.