Modernization has reduced polishing and cleaning time from about 30% to roughly 10% of production, while mold design and casting remain complex and pressure-sensitive, with internal pressures reaching up to 125 metric tons.

Mold integrity is critical due to extreme internal pressure when casting large bells, requiring high-quality clay and steel sleeves.

In Innsbruck, Austria, the Grassmayr Bell Foundry—founded in 1599—continues to cast multi-ton bells for churches in Italy, Germany, and Romania, blending traditional craftsmanship with modern technology.

The business is run by brothers Johannes and Peter Grassmayr, who combine time-honored methods with innovation, using tools like 3D printing, scanning, lasers, and computer simulations.

To sustain the craft, Grassmayr has focused on restoring old bells with modern tech, restoring hundreds of defective bells across 12 European countries.

The story highlights a tension between slowing demand for new churches and the need to preserve a historically important craft through adaptation and innovation.

The article is attributed to Matthias Schrader of AP, published July 29, 2026, with an updated timestamp two hours later.

Rising costs and shifting demand challenge the industry: fewer new churches are being built, energy costs have risen due to the Ukraine war, and labor costs have increased about 30% since 2020, making bronze the main variable in bell pricing.

Bronze material costs have surged, climbing from roughly 8 to about 23 euros per kilogram, directly influencing bell costs and financial planning.

Producing bells of several tons involves large-scale casting and stringent safety precautions for handling molten metal.

Some aspects of the process remain secret, such as a high-pressure sandblasting chamber and proprietary acoustics predictions.

Johannes Grassmayr emphasizes the core principle: calculate, form, and cast the bell as a musical instrument, while mold integrity under pressure remains the greatest casting challenge.