The neck is the kind of part where shape and dimensions are leading, not resonances. The fingerboard needs to be highly precise and the neck needs to be stiff. The demand I added is that it needs to be lightweight.
Fingerboard and neck are integrated into one hollow carbon shape
The neck is made out of carbon and epoxy, and the fingerboard and neck are integrated into one hollow shape. Since the outside shape and dimensions are leading, I find using molds to make the neck a convenient option.
Carbon is regularly used as a woven cloth that is impregnated with epoxy resin. The stiffness and (directional) strength can be increased by adding layers or using a thicker cloth. Since not all parts of the neck need equal stiffness and strength, the mold is a cast of the dimensionally accurate outer shell, and the layers are built up onto that shell from the inside. This way the dimensions are leading and the wall thickness can be varied to achieve the added goal of minimum weight.
Mold under vacuum, ready for the oven where the epoxy resin bakes to a solid
Another goal was the possibility to use normal strings. Normal strings have a length above the top nut where the string is made thinner, so it can be wounded around the tuner pegs more easily. This already narrows the options for drastic changes. Making it out of carbon might have been an option, but carbon isn’t good with point loads and it is also 2,5 heavier than maple (in density).
These logical arguments are actually a weak defence, because the real issue is that I love the traditonal scroll and pegbox too much to throw it overboard (it is not all rational…). And because the dimensions are again leading, the headstock is cnc-machined out of flamed maple.
Maple block for headstock
Bansawing maple block for headstock
Maple headstock blocks ready for cnc machining
cnc machining headstock
cnc machining headstock contour
cnc machining headstock pegbox