Klipsch headquarters walkthrough: behind the scenes and between the ears
By Darren Murph 
posted December 25th 2009 1:59PM
posted December 25th 2009 1:59PM
Just so you have some background, Klipsch's headquarters are located in Indianapolis, Indiana, with another major production facility located in Hope, Arkansas. The Indy HQ (where we visited) is home to a dedicated design lab, one of only a smattering of anechoic chambers in the world, an in-house painting facility, a construction lab (for building wooden mockups as well as cabinets and the like), an environmental simulator for testing product response to weather variations and an SLA machine that's used to create minuscule mockups of earbuds. Oh, and there's also a handful of extremely passionate employees, a few one-off speakers that were built but never sold and a corporate mandate that music must be played be played at all times. Just kidding on that last one.
Our tour started out with a roundtable discussion involving a number of Klipsch's best and brightest headphone engineers and product managers, and we simply asked them to tell us (and in turn, you) what exactly goes into designing some of the smallest speakers known to man. Klipsch itself hasn't actually been in the headphone business forever; a few years back, the outfit made a few check swings (and misses) in the sector, but it wasn't until it dove deeply into ear canal research that things started to come together. You'll notice that the outfit's entire range of earbuds (including the S2, S4, S4i, X10, etc.) sport ear tips that aren't exactly round. In fact, they're oval.
An engineer explained to us (and showed us boxes upon boxes of proof) that hundreds of ear impressions were gathered in the name of research, and while each one obviously boasted its own unique shape and size, one single characteristic remained uniform across the board: the entrance into the ear canal is not a perfect circle, it's an oval. For decades, in-ear headphones have been forcing users to shove circular tips into oval-shaped holes, and that certainly explains the nagging pain that generally sets in after a few hours of solid listening. Klipsch decided to change the game up, and just recently it was granted a patent for its oval ear tips. We've tested these tips against more conventional alternatives, and there's no question that the oval ones fit more comfortably (and for longer periods).
We were also shown the actual speaker mechanism used within the S4 and S4i, and while it was far smaller than even a raisin, engineers somehow managed to implement a dual magnet design for the added kick on the low-end. During the briefing, we were introduced to a pair of to-be announced products that the company let us talk about early. The first is the new black-and-white Image S4i, which is the first set of iPhone remote-equipped earbuds that Apple has sold in white aside from its own. We're told that these will be out early next year for $99, and based on the immense amount of color mockups we witnessed in the design lab, we're all but certain that more variations are on the way. The second is an iPhone-friendly version of the high-end X10 (dubbed the X10i, naturally), which will ship in early 2010 for $349.
We also inquired about Klipsch's stance on wireless, and the answers we received were certainly interesting. We mentioned our underwhelming reaction to Kleer's new W-1 wireless kit, and the staff tended to agree that existing wireless options simply weren't elegant enough to be considered a part of "a great user experience." From what we could gather, the team isn't interested in shipping a set of cord-free 'buds if a dongle (or two) are involved; they weren't shy in longing for Apple and the Bluetooth SIG to both put a greater focus on wireless technologies for audio, but until something completely outside of their control happens, it's probably tethered or bust.
Klipsch has certainly carved out a good chunk of market share in the segment, but it has no illusions of guaranteed success. Our camera was allowed to snoop around within some fairly classified pages detailing design ideas, comparisons with rivaling companies (Ultimate Ears, anyone?) and sketches of the next best thing(s). Speaking of changes, we were informed that a fourth set of ear tips may soon be joining the three that currently exist, with an "extra-small" version on the horizon to satisfy those with atypically small canal entrances.
If you're curious as to how exactly these things get created and tested, we've got plenty to share. We asked how exactly a speaker (or headphone) went from a far-out idea in someone's head to a shipping product, and essentially, there's a six step process that any given pipe dream is forced to wade through. For starters, a product is molded and defined; then, a project team is assembled to align demands with acoustics, shape, color, cost, etc. so that a compromise can be accomplished. Following that, a manufacturer is tentatively chosen, the development is initiated, the product is verified and a launch is given the green light. We were told that the process typically takes between 8 and 12 months, though some fast-tracked wares have been shot through in 6 months -- though, such a speedy (and pricey) turnaround generally requires an engineer or two to live in China so that design samples can be inspected, tweaked and okayed on the spot.
The in-house construction facility was a real stunner. In essence, it's a single room with a single mad scientist, and hardly any rules to speak of. The lone ranger running the show can receive designs that were created in SolidWorks and convert the code into instructions for one of two precision cutting machines to grab hold of. Essentially, this facility enables Klipsch to generate wooden mockups of speakers, cabinets, etc. on the spot, enabling the turnaround time to be shortened significantly. As you'd expect, this method also allows the company to keep its next-gen designs close to the chest. There's also an accompanying paint factory as well as a lighting simulator that gives the company the ability to test out different hues and coats under varying lights -- after all, the lighting within a Best Buy is drastically different than the lighting outside or within your home.
If a mockup is too small for a drill bit to carve out (like, you know, an X10 earbud), the instructions go to a quarter-million dollar SLA machine. For those unfamiliar with stereolithography, the machine takes 3D CAD instructions and funnels them to a laser. The laser pinpoints a vat of underlying UV-curable goop, and as minuscule portions of the liquid are frozen in place, new layers are placed on top and the process begins again. Eventually, a hardened model emerges from the mire, and from there, it's baked in a specialized oven. It's pretty remarkable how detailed this system can get, and we've got plenty of shots in the gallery below (as well as a brief video of the laser in action).
Once products are actually built in Asia and shipped back to Indy, quality assurance kicks in. An environmental simulator enables speakers and earphones to be battered in ways mere mortals wouldn't even think about, and given that some of these products end up in stupendously humid regions of India and staggeringly cold portions of Canada, it's critical that products can withstand the pressures that they'll (possibly) be faced with. Rain, humidity, extreme heat / cold -- you name it, and this machine can unleash it. Klipsch maintains an internal list of acceptable benchmarks when it comes to reliability, and if any product fails to meet said marks, the company is forced to go back to its Asian manufacturer in order to implement the needed tweaks.
Our last stop was a real treat. The company's anechoic chamber is accessible within the main building, but it's actually its own separate entity. The building is mounted on loads of underground springs, and the walls, floor and ceiling are coated with triangular slabs of foam. The purpose? To test any given speaker's frequency response. We were actually locked within the chamber and asked to speak to someone, and we have to say, the sensation of talking and not hearing even the faintest echo is indeed surreal. When gadget editors aren't yodeling within it, Klipsch actually places a single speaker on a rotating stand and points it directly at one of the most expensive microphones on this great planet. Once the door is air sealed, a variety of frequency tests are ran in order to determine where crossovers are needed and what frequency specifications should be published on the packaging. Have a peek at the video we took of a live test while standing inside -- but be warned, some of the frequencies are downright ear-piercing.
In case you're hungry for more from within the Klipsch lairs in Indiana's capital, feel free to poke around in the galleries littered about. Our major takeaway is that speaker (and particularly earbud) creation is a huge, huge undertaking, and nailing a design is no small feat -- particularly when you've got consumers demanding more for less. We also get the idea that many of the process steps that are taken in speaker / headphone development takes place in other sectors, though we'd also surmise that smaller outfits like Klipsch can generally take products from concept to commercialization far quicker than larger firms. Unfortunately, after all of this, we still can't promise a hard release date for those hot pink and neon green headphones. But trust us, we're working on it.
From the moment I damaged my left ear with a stupid Johnson & Johnson Q-tip I have never been able to use any of those into-the-ear-canal earphones.
But the settlement got you a brand new lamborghini right?
@TikiTeko hmm no lol.. it never occurred to me.. it was my fault anyways... you are not supposed to push them too much in. I really miss listening to music as I did before. :S It pains me to now be unable to do it full duplexly. *Also, I was young and stupid - I think like 15. Why is it that young people get in so much trouble for pushing things incorrectly
"video not available"
@Wwhat
Same here, I am very disappointed
Video is up now.
@Wwhat Apologies for that! It's live now.
Oh don't worry about it, I had full confidence it would be fixed.
I live in Indy and took a tour a couple years ago. Amazing facility and knowledgeable employees.
The anechoic room is pretty awesome, almost weird sounding inside.
--edit--
I just picked up a set of the S4 ear-bud's... Wow, best in-ears I have ever owned.
This is some really impressive production process they got. Thank you engadget! and klipsch.
The video's are not available. WTF?
@markntravis I too would like to know. WTF!
Flux Capacitor is... fluxing
Awesome Engadget. I've been a fan ever since I purchased my promedia 2.1 speakers 6 years ago. Thanks for the tour.
Working hard, Darren?
@DestrictoEnse Oh yeah bro -- somebody's got to do it! :-)
Klipsch > Bose
@MONKEY I've never been impressed by Bose. I think it is more hype and branding than anything else. But I've never tried this brand, in fact, this is the first time I read about it - and I dwell in technology forums and I am an music fan.
What kind do you have? What products from them?
@MONKEY agreed. I have Klipsch computer speakers, and my Home Theater is a set of Klipsch Reference Series. I love them, sound is so amazing!
I was never too impressed with Klipsch's home speakers. Their sound is generally much too bright for my tastes. I haven't heard their Heritage series, though, which I've been told are the only Klipsch speakers worth listening to. I do like the Promedia 2.1s, though. And they make a mean headphone. In fact, I'm listening to my Image S4s right now.
i got a pair of klipsch S4 earphones today, and they are absolutely lovely. i thought they were comfy when i first put them in, and hours later i realized i had L and R reversed... swapping them to their correct ears triggered what can only be described as an eargasm. get them. http://reviews.cnet.com/headphones/klipsch-image-s4-earphones/4505-7877_7-33577358.html?tag=mncol;lst
As I was watching one of the videos, a JBL ad came up. Oh, the irony that Google Ads create... Did you notice any plans for Klipsch to become integrated into cars that you noticed while in the HQ?
@doboy I didn't, but I wouldn't put it past them. I think once they get a real handle on the lower-end consumer market, automotive may be their next target. Or one of their next targets.
I really enjoyed this article.
thanks Engadget.
Neato!
Awesome article! A wannabe audiophile such as yours truly loved it.
Is it bad if one can only heard from about 00:25 - 00:35 of that last clip? :D
Thanks Darren for a great article on a great company. I currently own a set of bookshelf speakers from Klipsch, and an quite happy with them.
I bought them because my cousin bought the legendary Klipschorns back in the day, and have wanted a pair ever since. Unfortunately, I cannot afford them now or for the foreseeable future :(
Great article. The fact that Klipsch is willing to open their doors and give a behind the scenes look at their company sure says a lot about the passion and drive they have as an audio company.
On another note, I'd love to see more behind the scenes look at other companies as well.
I am still amazed that people need to post a SLA machine at work. I've been working with SLA parts on a weekly basis for over 15 years. boring. :)
Now we are loosing against sone .... People and soo. The robots might take over the highest positions. I wonder what hymn we are going to sing then ?
@pankomputerek sory for my spelling written on a phone.....
Owner of the promedia 4.1 speakers for 7+years, still going strong and I still love them! go klipsch!
They may know how to make speakers but I'm not buying any. I bought the Promedia 5.1 system only to have the subwoofer die multiple times. I thought it was just me until I did a Google search and found that this happened to a ton of other people.
@DeWaters1
Had the same problem with mine a few years after purchase, I sent it to them they repaired for under 70 bucks. Was it an inconvenience to have to do it? Yes. Was I satisfied with the repair? Yes. Would I buy Klipsch again? Absolutely. Had I been in warranty, they would have done it for free. Just the fact they could and would repair a six or seven year old product was good enough for me.
I subsequently purchased two RF-35s, two RB-81s, an RPW-10, an RC-52 and two RS-7s for the home theater.
Audio is like wine, everyone has their own tastes, Klipsch suits my palette.
Awesome feature Darren, Thnx a lot.
@Munk Thanks, appreciate it!
i own a pair of rf 83 floorstanding (and other klipsch)and its a remarkable speaker.or should i say monster?!(100lb).its beautiful to look at (without the grill) and its sounds amazing.if you can afford it or if you can get a good deal on them ,just buy them without listening to it.
is that a new floorstanding on the picture or just a prototype?