It takes a lot of work to craft the workshop’s trademark bells capable of producing such a solid timbre and the first step begins with creating the right mold. Using a mixture of earth, clay, and rice husks to form the mold, this initial step is of great importance as if not done correctly gasses will be trapped during the alloy casting which will distort the shape and sound of the final product. During this stage it is also necessary to carefully maintain and monitor the temperature otherwise the work will prove to be all for nothing and the molds and flawed bell will have to be recycled and the process forced to begin again in the pursuit of perfection. 

In order to obtain a consistent quality of sound, the Nanjō Foundry produces its own metal alloy onsite according to a method and recipe that dates all the way back to the workshop’s founding in 1839, making this foundry one of the few in Japan to enjoy such a direct and unbroken link to past methods. Passed down throughout generations, this mixture is known as “sahari” and is an alloy of copper and tin unique to the foundry. 

Once this alloy is prepared, it is manually cast at just the right temperature to ensure even cooling of the final product. Once sufficiently cooled, the molds are broken and the “orins,” or “singing bowls,” are extracted and inspected for shape, form, and tone. Any not conforming to the foundry’s strict standards will be recycled as will the molds and all materials will be reused so that nothing goes to waste during the production process. And in order to achieve the best possible sound it is not unheard of that these fresh singing bowls may be recast dozens of times in pursuit of a sound that will not only appeal to Buddhas, Bodhisattvas, the Kami (the native gods of Japan) but also to the discerning ears of demanding musicians.