JL Audio has extensive in-house manufacturing capabilities, including a large woodworking area. There were numerous computer numerically controlled (CNC) milling machines in use during our visit. Various types of wood -- MDF, HDF, plywood, etc. -- were in evidence, and stacks of finished parts were everywhere. JL likes to build as much as they can in-house. In fact, we learned that JL Audio even makes much of the furniture being used within the company offices!
On the day we visited, the machines were busily cranking out the MDF mounting boards used to transport W7 woofer drivers. These boards make it easier for customers to remove the drivers from their boxes and safely mount them in place.
The CNC machines ensure accurate cutting tolerances for the various parts that go into the JL Audio speaker cabinets.
Cut MDF is used for a variety of JL Audio speaker products, including the carpeted enclosures used for many of their automobile subwoofer cabinets.
The newest JL Audio home subwoofer systems, the in-wall IWS-SYS-1 ($4500) and IWS-SYS-2 ($7500), are seen here shortly after assembly. What might look like a simple box in finished form is actually quite complex. A closer look inside reveals . . .
. . . the honeycomb bracing system that keeps the thin-walled plywood cabinets stiff and resonance free. If you look closely, you can even see channels that are routed out of the wood for the cabling to run through. The labor involved in producing the in-wall subwoofers is as extensive as it is impressive.