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Have you ever wondered how a record is manufactured? Read on to reveal the mysteries of this complex and fascinating process.
The manufacturing process begins with the creation of a master recording, historically using tape but typically these days in a digital format. Experienced audio engineers then master the music, carefully adjusting levels, EQ, and dynamic range to optimize the sound for vinyl. The mastered audio is then transferred to a lacquer disc using a cutting lathe. The lathe’s stylus meticulously etches the grooves, translating the music’s vibrations into physical imprints. If you want to read a super detailed description of the cutting process check out this article.
The lacquer disc, known as the “master,” is coated with a conductive metal layer, often silver or nickel, to facilitate electroplating. It is immersed in a bath of electrically charged chemicals, where a thin layer of metal is deposited onto the lacquer. This step creates a durable metal “negative” called the “father” that serves as the mold for future record production.
The father undergoes meticulous cleaning and is placed in a chemical bath to remove any impurities. It is then coated with a release agent and dipped into a bath of nickel, which creates the “mother” stamper. The mother stamper, a mirror image of the father, preserves the intricate grooves of the original master recording.
The mother stamper is mounted onto a hydraulic press. Vinyl pellets, made from polyvinyl chloride (PVC) resin, are heated and melted. The molten vinyl is injected into the pressing machine’s mold, between the two stampers. The press applies immense pressure, causing the vinyl to take on the shape of the grooves and bond with the stamper. This process creates the “biscuit” or “puck” that will become the record.
The biscuit is transferred to a hydraulic press, where it is sandwiched between two labels, typically made of paper or cardboard, known as the center labels. The labels often display album artwork, track listings, and other relevant information. The press applies heat and pressure, causing the biscuit to spread out and take the shape of a disc while simultaneously embedding the center labels.
The newly formed vinyl record is then cooled rapidly, solidifying its shape. Excess vinyl around the edges, known as the “flash,” is trimmed off, leaving behind the final record’s distinctive circular shape.
To ensure quality, a sample record from each batch undergoes rigorous testing for sound quality, surface defects, and dimensional accuracy. The approved records are cleaned, placed in protective sleeves, and carefully packaged for distribution. Additional packaging elements such as album covers, inserts, or posters are added, depending on the release.
The manufacture of a vinyl record is a labor-intensive and intricate process, demanding meticulous attention to detail and craftsmanship. From the initial mastering and cutting to the final pressing and packaging stages, every step contributes to the creation of a tangible piece of music history. The revival of vinyl records has rekindled the appreciation for physical media, reminding us of the unique pleasure derived from holding and listening to music on a format that has stood the test of time.
