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Luckily there are still a handful of outfitters using DMM operating in Europe. This is where the Master was made.
Electroforming, sometimes referenced as Electroplating, is the process of making a copy of the lacquer Master in a fortified material that will be able to withstand the pressures of mass replication. First, it is sprayed with a silver solution to create a copy called a Mother. Next, the Mother is placed in a nickel bath to create a Stamper. Stampers have raised grooves used to press indentations into vinyl. For larger runs, a three-step process is used to create a Father, from which many Mothers and subsequently Stampers can be created.
Depending on the number of records that need to be pressed, there will typically be a few Stampers made. Releases with more than 10, records in the batch will usually undergo three-step electroforming. Each Stamper is taken to a hydraulic press, which stamps it down onto pre-heated vinyl material. This material starts out as pellets, which are formed into a solid hockey-puck shaped disc known as the Biscuit.
The Biscuit is sandwiched between labels on the top and bottom. The Stampers act in a similar fashion to a waffle-iron, with raised grooves that permanently imprint vinyl-material when applied with enough pressure.
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- The Vinyl Manufacturing Process?
Behind the scenes: Biscuits come in different weights, ranging from grams at the low end to more than grams at the high end. Next, the edges of the new vinyl record are softened, rounded and trimmed.
How It’s Made
The vinyl record is then cooled with a dip in water and set out to cure. How labels are attached to vinyl records: Most modern labels do not require adhesive. Pressure alone fuses the label to the polyvinyl chloride during the pressing process. Before labels are pressed onto vinyl records, they are baked in a special oven to eliminate moisture, otherwise bubbling may occur.
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After pressing, the record must be properly trimmed, cooled and then safely set aside for final curing. Have you ever opened a brand new release to find the vinyl warped? You may have also spotted that this has just made a one-sided stamper.
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- The Basics.
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PVC pellets are melted and shaped into a malleable patty-type lump imagine a delicious rubbery mini-burger made out of tasty-tasty PVC. The edge of this record is then spun against a knife, cutting away the ragged edge. The whole process of pressing and trimming the record takes under 30 seconds. Also determined in the pressing stage — the PVC pellets can be coloured, and mixed to create different tones of the finished record. Too much information for the main post…but when making the lacquer discs a hydraulic puncher cuts a hole in the centre for the disc to be held on the lathe and in the tank for electro-plating.
When the stamper is separated from the lacquer disc, an engineer puts the metal disc under a microscope which is attached to an optical-cantering punch seriously , and by rotating the disc the grooves are aligned with a guide in the viewfinder, and a hole is punched in the exact centre.
How Record Players Work
Along with various quality control checks e. Home Projects Events About. Our doors are always open and we are happy to collaborate and share the magic of vinyl experience with our partners.