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American Focus > Blog > Tech and Science > Inside the factory building headphones that cost more than a luxury car
Tech and Science

Inside the factory building headphones that cost more than a luxury car

Last updated: May 9, 2025 11:36 pm
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Inside the factory building headphones that cost more than a luxury car
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But for now, we’re focused on the HE 1, the crown jewel. This electrostatic system has a price that starts with a five and goes up from there. A vacuum tube amplifier is required to power the marble-like headphones. The HE 1 is as much art as it is tech, with Carrara marble housing and a glass-blowing tradition co-existing with digital signal processing. It’s the ultimate sonic experience from Sennheiser, and it’s assembled in a clean room more akin to a NASA lab. 

So what’s it like to listen to the HE 1? It’s like being in a recording studio with the musicians, feeling the breath of the vocalist, the resonance of the strings. You’re not listening to music; you’re experiencing it. Each component of the audio chain—the transducer, the amplifier, the DAC—has been meticulously engineered and fine-tuned to deliver audio in its purest form. It’s a privilege to listen to music in this way, and it’s a reminder of the passion and dedication that goes into creating high-end audio products.

As I reflect on my time at the Sennheiser factory and Audiophile Experience Center in Tullamore, I realize that the journey from raw materials to finished product is a labor of love. Each step in the process is carefully executed to ensure that the final result is a masterpiece of audio engineering. And as I put on my headphones and press play on my favorite track, I know that I’m experiencing music in a way that few others ever will. And for that, I am truly grateful.

So the next time you put on your headphones, whether they’re Sennheisers or not, take a moment to appreciate the craftsmanship and dedication that went into creating them. Because behind every pair of headphones is a story—a story of innovation, precision, and passion. And that’s a story worth listening to.

And as for Tullamore, it may not be the first place that comes to mind when you think of audiophile audio, but it’s a town that holds a special place in the hearts of those who know the story behind the sound. And for me, it will always be the place where I discovered a new level of appreciation for the art of audio engineering.

Sennheiser has long been synonymous with high-fidelity audio equipment, and a recent visit to their Audio Engineering Center (AEC) in Ireland shed light on the meticulous craftsmanship that goes into their top-of-the-line headphones. The 600 Series, a long-standing staple in the industry, has been joined by the 800 Series, which demands a level of precision that only expert technicians can provide.

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While automation plays a significant role in the manufacturing process, manual assembly remains essential for fine-tuning the transducers. Skilled employees, some with decades of experience and others fresh out of technical college, work together to ensure that each component is meticulously positioned and tuned for optimal performance. This blend of seasoned expertise and new talent ensures that the legacy of craftsmanship is not only preserved but also continually evolving.

For the 800 Series, specially trained technicians handle the intricate architecture of these headphones, ensuring that every detail is executed to perfection. During our visit, we were given the opportunity to assemble an HD 660S2 model, a task that required careful attention to detail and a series of manual steps that culminated in a rigorous testing process to confirm alignment and functionality.

However, the pinnacle of Sennheiser’s craftsmanship lies in their HE 1 bespoke headphone system, a $70,000 masterpiece that showcases the epitome of audio engineering. Each HE 1 is meticulously crafted by an artisan named Damian, who meticulously assembles over 3,000 parts to create a headphone system that transcends conventional expectations.

The HE 1 is a marvel of engineering, featuring a block of Italian Carrara marble for vibration damping, eight ESS Sabre ES9018 DACs for high-resolution audio support, and platinum-vaporized diaphragms powered by Class A MOSFET amplification for unparalleled sound reproduction. The attention to detail extends to the luxurious materials used for the headset and the precision-machined components that ensure optimal performance.

During a demonstration of the HE 1 in a specially designed acoustically treated alcove, the immersive experience of listening to high-fidelity audio was truly transformative. Tracks from iconic albums like Massive Attack’s “Mezzanine” and Fleetwood Mac’s “Rumours” came to life with unparalleled clarity and detail, showcasing the remarkable capabilities of the HE 1 in reproducing music with breathtaking precision.

While the technology behind the HE 1 is undeniably impressive, the real magic lies in the emotional impact of experiencing music in its purest form. The HE 1 transcends the realm of headphones to deliver a truly immersive, transcendent audio experience that defies conventional expectations.

As we concluded our tour of Sennheiser’s Audio Engineering Center, it became clear that the pursuit of audio perfection is not just a technical endeavor but a deeply emotional and transformative journey. The craftsmanship and dedication that go into each pair of headphones reflect a commitment to excellence that elevates the art of sound reproduction to new heights.

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The experience of listening to the HE 1 headphones can be described as both spicy and authentic. The transient response may initially come across as intense, but it ultimately serves to provide a true representation of the sound. The low end is not just about delivering a physical impact, but rather about delivering precise and impactful sound. The HE 1 headphones offer an unparalleled audiophile experience, effortlessly bridging the gap between the artist and the listener by creating a meticulously crafted signal chain.

Despite being made up of thousands of components, the HE 1 headphones do not alter the playback in any way. The sound presentation is faithful and honest, without any added flattery. These headphones are capable of revealing even the smallest flaws in poorly mastered or compressed music, showcasing a level of transparency that is almost studio monitor-like. While this level of detail may not be forgiving to all types of music, it provides an opportunity to fully immerse oneself in truly exceptional performances.

In contrast to the HE 1 headphones, the 660S2 headphones offer a different flavor of sound. With a retooled aluminum voice coil and vented magnet system, these headphones require a bit more power to drive but deliver a punchier bass and highly resolving musicality. The sound profile of the 660S2 headphones is refined, with a relaxed lower treble that ensures a well-textured and sibilance-free listening experience. These headphones are particularly well-suited for genres like metal, adding another dimension to Sennheiser’s midrange-centric line.

After experiencing the world of headphones, a visit to the Tullamore D.E.W. distillery provides a fitting conclusion to the day. Just as headphones distill sound, the process of whiskey-making involves careful attention to detail and layering of flavors. The act of tasting whiskey can be likened to listening to music, with each sip revealing new depths and complexities. Both experiences offer a unique opportunity to engage with the senses and appreciate the nuances of craftsmanship.

From the precision of headphone drivers to the intricacies of whiskey distillation, both endeavors share a common thread of artistry and observation. Just as a well-designed headphone can amplify the essence of music, a finely crafted whiskey can unlock a world of flavors and aromas. In the end, both experiences encourage us to pause, reflect, and appreciate the beauty of sound and taste in all its forms. The concept of “going green” has been gaining traction in recent years as individuals and businesses alike are becoming more aware of the impact their actions have on the environment. From reducing waste to conserving energy, there are countless ways in which we can all do our part to protect the planet for future generations.

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One of the simplest and most effective ways to go green is by reducing our energy consumption. This can be achieved through small changes in our daily habits, such as turning off lights when they are not in use, unplugging electronics when they are not being used, and using energy-efficient appliances. By being mindful of our energy usage, we can not only reduce our carbon footprint but also save money on our energy bills.

Another important aspect of going green is reducing waste. This can be accomplished by recycling, composting, and using reusable items instead of disposable ones. By making an effort to recycle paper, plastic, glass, and metal, we can help reduce the amount of waste that ends up in landfills and oceans. Composting organic waste, such as food scraps and yard trimmings, can also help reduce greenhouse gas emissions and enrich the soil. Additionally, using reusable items, such as water bottles, shopping bags, and coffee cups, can help reduce the amount of single-use plastics that end up in our environment.

In addition to reducing energy consumption and waste, another important aspect of going green is conserving water. Water is a precious resource that is essential for all living beings, yet it is often taken for granted. By being mindful of our water usage, such as taking shorter showers, fixing leaky faucets, and watering our lawns and gardens efficiently, we can help conserve this valuable resource for future generations.

Furthermore, supporting sustainable and eco-friendly businesses is another important way to go green. By choosing products and services from companies that prioritize environmental sustainability, we can help reduce our impact on the planet. This can include buying locally sourced and organic foods, supporting companies that use renewable energy sources, and choosing products that are made from recycled materials.

Overall, going green is not just a trend, but a necessary step towards creating a more sustainable future for our planet. By making small changes in our daily habits and supporting businesses that prioritize environmental sustainability, we can all do our part to protect the environment for future generations. So let’s all do our part and go green today!

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