Good questions Tom! I’ve pondered these issues frequently in the past, and reached the conclusion that, for me personally, it is a fundamentally over constrained problem.
What do I mean by that? Well, you frequently hear people complaining, or perhaps just airing their frustrations, about the following things:
- Price: Anything more than a penny (or a few pennies) for a “penny whistle” is way too much.
- Quality: If its made from cheap materials, such as plastic or thin sheet metal, it is not a quality instrument.
- Knock-off: If its a mass produced version of an earlier design, then someone is ripping someone else off.
- Inconsistency: playing characteristics should fall within a very tight window.
- Not made here: If its made somewhere else where labor is cheap, then we should not buy it, out of patriotism and loyalty to local makers. Plus those foreigners are not to be trusted.
So, its clear that to be considered legitimate, you will have to use expensive materials to make an original design of your own, finish and fine-tune every instrument by hand to high quality standards, live in the same country as your customers, and sell your instruments for a fraction of the cost of the raw materials!
Seriously, though, it is quite difficult to make a really good whistle because the tolerances in the head are so fine, and slight differences have a big impact on the playability.
You can address this by fine tuning every one by hand, but then you have huge labor costs per instrument.
Or you can address it by building a high precision manufacturing system, but then you have huge up front costs and will spend your time in a completely different way.
Or you can try to outsource and manage quality control and consistency remotely.
For me personally, I’m interested in making instruments by hand (more as a hobby than a profit making business), and the amount of work taken to make a quality whistle by hand, combined with the costs of materials and tools, is just incompatible with price point expectations for inexpensive whistles, even at $100 a piece.
Its arguably easier to make a consistently good keyless flute than a consistently good whistle, but the two instruments command radically different price-point expectations.