I was recently asked, off forum, "Don't you also agree that good rolled tone holes are one of the best features on any Saxophone?"
I thought my answer would be of interest to others, and some may like to disagree, so I have posted it here......
There are distinct disadvantages:
1. As with flutes, it is difficult, possibly impossible to get accurately level tone holes - 0.02 mm discrepancy represents a significant leak). Manufacturers are not good at achieving this. The rolling process typically leaves the tone hole edge too high where the tone hole wall is lowest, i.e. 'north' and 'south'. Dealing with this is not easy, and presents a good opportunity for a less scrupulous technician to be a 'butcher'.
2. There is a higher surface area of metal contacting the pad. Therefore more finger force is required on a key to create sufficient localised pressure on the 'sealing circle' to overcome blemishes in the pad surface and irregularities in the tone hole levelness, to seal a pad on its tone hole.
3. If there is damage to the sax, e.g. a local dent or 'fold', that distorts, or even creases the tone hole, it is far more difficult to for a technician to restore a rolled tone hole.
4. Pads sticking to tone holes is a pretty big problem with saxes. Rolled tone holes present a larger surface area, which greatly increases the likelihood of a sticky surface on the pad sticking to the tone hole. (A burr on an unrolled tone hole can also be a cause of stickiness, but this can be permanently dealt with)
Perhaps the only advantage of rolled tone holes on a sax is that the pads will take a little longer to cut through. However the first indication that pads need changing is normally that they have hardened - the leather and/or the felt. Rolled tone holes are unlikely to reduce this hardening. After pad leather has hardened it splits or cuts quite easily, but less likely over rolled tone holes. I have worked on many rolled-tone-hole saxes where the pads are very hard and leaking profusely, but still LOOK OK. They are long overdue for replacement.
To manufacture a sax with well-levelled, burr-free, non-rolled tone holes is probably more difficult than to whip up somewhat-irregular, rolled tone holes.
Rolled tone holes have become almost universally standard on student flutes, and many expensive ones too. This is partly because non-rolled tone holes, with the rather thin metal of flutes, quickly cut through the much more fragile membrane of flute pads. Item 2 is not so relevant, because flute tone holes are generally so much smaller. Item 4 is less relevant, because for saxes, much of the stickiness is due to sticky materials embedded in the porous leather pad surface, including verdigris, which typically does not form on flute pads, flutes being a more corrosion resistant metal surface. Flute players tend not to blow gunge down their flutes! The non-levelness of rolled tone holes common on student flutes is a big problem.
The best professional flutes have soldered tone holes, made from metal thicker than the body of the flute. Sadly, soldered tone holes cope poorly with jarring or bending of an instrument, and galvanic corrosion at the solder joint. These issues are more significant with the large body of a brass sax, than they are with a precious-metal flute.
I thought my answer would be of interest to others, and some may like to disagree, so I have posted it here......
There are distinct disadvantages:
1. As with flutes, it is difficult, possibly impossible to get accurately level tone holes - 0.02 mm discrepancy represents a significant leak). Manufacturers are not good at achieving this. The rolling process typically leaves the tone hole edge too high where the tone hole wall is lowest, i.e. 'north' and 'south'. Dealing with this is not easy, and presents a good opportunity for a less scrupulous technician to be a 'butcher'.
2. There is a higher surface area of metal contacting the pad. Therefore more finger force is required on a key to create sufficient localised pressure on the 'sealing circle' to overcome blemishes in the pad surface and irregularities in the tone hole levelness, to seal a pad on its tone hole.
3. If there is damage to the sax, e.g. a local dent or 'fold', that distorts, or even creases the tone hole, it is far more difficult to for a technician to restore a rolled tone hole.
4. Pads sticking to tone holes is a pretty big problem with saxes. Rolled tone holes present a larger surface area, which greatly increases the likelihood of a sticky surface on the pad sticking to the tone hole. (A burr on an unrolled tone hole can also be a cause of stickiness, but this can be permanently dealt with)
Perhaps the only advantage of rolled tone holes on a sax is that the pads will take a little longer to cut through. However the first indication that pads need changing is normally that they have hardened - the leather and/or the felt. Rolled tone holes are unlikely to reduce this hardening. After pad leather has hardened it splits or cuts quite easily, but less likely over rolled tone holes. I have worked on many rolled-tone-hole saxes where the pads are very hard and leaking profusely, but still LOOK OK. They are long overdue for replacement.
To manufacture a sax with well-levelled, burr-free, non-rolled tone holes is probably more difficult than to whip up somewhat-irregular, rolled tone holes.
Rolled tone holes have become almost universally standard on student flutes, and many expensive ones too. This is partly because non-rolled tone holes, with the rather thin metal of flutes, quickly cut through the much more fragile membrane of flute pads. Item 2 is not so relevant, because flute tone holes are generally so much smaller. Item 4 is less relevant, because for saxes, much of the stickiness is due to sticky materials embedded in the porous leather pad surface, including verdigris, which typically does not form on flute pads, flutes being a more corrosion resistant metal surface. Flute players tend not to blow gunge down their flutes! The non-levelness of rolled tone holes common on student flutes is a big problem.
The best professional flutes have soldered tone holes, made from metal thicker than the body of the flute. Sadly, soldered tone holes cope poorly with jarring or bending of an instrument, and galvanic corrosion at the solder joint. These issues are more significant with the large body of a brass sax, than they are with a precious-metal flute.