The Fascinating Process of Vinyl Record Making Explained
Summary
Get an exclusive, in-depth look into the vinyl record-making process, from cutting the lacquer to quality control, and understand the effort that goes into creating the rich, textured sensory experience of listening to vinyl records.
Table of Contents
- The Lacquer Coating and Cutting Process
- The Importance of the Programmer and Stylist in Lathe
- Details on Grooves and Record-making Process
- Electroplating and Stamper Creation
- Pressing Process and Quality Control
- Conclusion
The Lacquer Coating and Cutting Process
The vinyl record-making process begins with coating the lacquer, and most records you’ve heard have been done on lacquer. Lacquer is similar to nail polish but hasn’t fully hardened yet. In vinyl record-making, a company called MD from Japan supplies the lacquers used. A lathe, such as the 1974 VMS 7, is used to cut the lacquer, which takes about 2.5 hours. The stylist cuts the lacquer, and the hot chi collects the excess lacquer at the bottom. The programmer is another important part of the lathe, holding all the details of cutting a 12-inch 3, 12-inch 4, 7-inch 4 or even a 10-inch record. A 12-inch record has about 19 minutes of songs per side, equating to about 300 to 400 lines per inch with small grooves per side.
The Importance of the Programmer and Stylist in Lathe
The grooves on a vinyl record create sound as the stylist moves back and forth, up and down, and creates vibrations. A total of 127 things can go wrong in the process, where any heat-related issues can burn the lacquer or cause excessive noise. To prevent any such issues, the lacquer is heated and cooled with helium to achieve a balance. Using nitrogen to clean the lacquer and methyl ethyl ketone for the stylus is necessary to preserve sound quality. Nitrogen ensures the lacquer stays clean during cutting, and the color-coded jigs guide the placement of the cutting head to avoid any damage.
Details on Grooves and Record-making Process
Once the lacquer cutting is complete, a lock groove is created to complete the record. The next step is etching the matrix number, which is done by hand and is a small and difficult task. A master disc is created from the lacquer by electroplating, which is accomplished by covering the lacquer with silver nitrate and dipping it into a nickel bath. The stamper is a reverse image of the lacquer. Test pressing and quality checks are performed on the stamper, ensuring that sound quality is up to par. Every time a stamper is changed, a stringent cleaning process is done to ensure there’s no dust or debris.
Electroplating and Stamper Creation
Once the artist gives their approval on a test pressing, the record is ready for production. This process involves prepping the labels and dialing up the extrude to obtain 200 grams of vinyl grade PVC, which is then placed into the press. The pressing process lasts for about 45 seconds in a heated chamber, and the vinyl is pressed into a mold with high pressure steam. The vinyl is left to cool, and the outer edge excess vinyl is trimmed before a visual inspection is completed. The vinyl is then tested for audio quality, checking for swishing noises or no-fil issues, among other things.
Pressing Process and Quality Control
In some cases, inspection of the groove may be necessary to test for wavering or inconsistency, which could result in an altered audio experience. Operators can adjust the settings at the press to resolve any issues. Finally, the vinyl is flattened, labeled, packaged, and prepared for shipping.
Conclusion
Vinyl records are a tangible three-dimensional experience that engages our nervous system and helps us heal, providing a rich, textured sound that is like a vitamin for our souls. By understanding the vinyl record-making process, we can appreciate and admire the effort that goes into producing this timeless sensory experience.
