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The Manufacturing Process of a Metal Pea Whistle
The following process is used to manufacture the type of metal pea whistle that is commonly associated with American military, police, and sports applications.
1. Sheets of brass are unrolled from supply reels and fed into stamping
machines. Blanks are die-cut for the whistle's three primary pieces: the
rectangular air-input tube, the barrel-shaped chamber, and a fitting for the
back of the whistle that will hold a ring to which the user can attach a
lanyard (cord). Different grades (hardnesses) of brass are used for the
two main functional pieces of the whistle.
2. The pieces pass through a series of stamping dies and presses that
perform a progression of cutting and bending operations to form them into
the required shapes. The company name (or a customer's custom logo) is
stamped onto what will become the top of the whistle.
3. Custom-designed machines hold the three parts of the whistle in position
while solder is applied to the joints and the assembly is heated, sealing the
parts together.
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Pea whistle blanks are die-cut for the whistle's three primary pieces: the rectangular air-input tube, the barrel-shaped chamber, and a fitting for the back of the whistle that will hold a ring to which the user can attach a lanyard (cord).
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4. Each whistle is mounted in another machine, where a vibratory sander
smooths the exterior surface to a pre-plate finish.
5. A nickel or chrome plating is applied to the exterior of the whistle.
6. The cork ball is inserted in the whistle. A machine compresses the cork and
shoots it through the slot on top of the whistle. Once inside, the cork
returns to its original shape, making it too large to fall out through the slot.
7. A metal lanyard ring is inserted into the holder on the back of the whistle.
8. Standard whistles are packaged in a plastic bubble attached to a cardboard
backing. More expensive versions, suitable for use as gifts or awards, are
mounted in a plastic box or a wooden case.
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