This video shows the machining of a Wedge Delrin mouthpiece top. Machining Delrin does not require coolant, so it is easier to see what is happening. The first cut is a horizontal rough cut using a 1/4 inch ballnose endmill and a 10% step down and step over. RPM is 5100. The second finishing cut is with a 1/8th inch ballnose endmill at 5100 rpm and a 2/1000 inch step over. Index marks are added at the end.
The machining process takes about 40 minutes all together. The mouthpiece will then be spin polished by hand in the lathe using 320, 400, and 600 emery cloth followed by two different plastic polishes on cotton to produce a smooth finish. The machining time for these Delrin mouthpieces is the same as brass, and the cost of materials is just slightly less. They are offered at about 50% of their actual retail value based on production costs in order to give people an economical way chance to try the Wedge.
A Wedge Delrin top with a stainless steel backbore is very comfortable, is very responsive, and produces a sound just slightly darker than brass. I choose to play a Derlin top on a stainless steel backbore for all of my playing. Delrin tops are available for trumpet, cornet, flugel, trombone, and tuba. French horn Delrin models coming soon.
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