Vinyl Manufacturing
To make a vinyl record, the master audio is cut from the source onto a blank lacquer disc using a lathe. Using something that looks like a large turntable, a stylus uses pressure to carve grooves on the master lacquer based on the music's sound waves.
Prior to lacquers, direct metal mastering (DMM) was used. Developed in the 1980s, DMM used a specially equipped lathe to cut grooves into blank copper discs. However, lathes have since been converted to cut lacquers instead of copper discs.
After the lacquer is cut, a stamper is needed. The master disc is washed before it’s sprayed with tin chloride and liquid silver. Excess metal is removed and the lacquer is fastened onto a hydraulic press. This process, known as electroplating, creates the metal parts needed to stamp the grooves into each record.
Before the records are made, labels need to be created. Holes are drilled in the middle of each label, and they are trimmed into circles.
Polyvinyl chloride (PVC) is poured into a hopper, which subsequently goes into an extruder that condenses them. When the PVCs get condensed, they turn into a hockey-puck shaped piece of extruded vinyl called a biscuit. The hydraulic press machine then places the labels on both sides of the biscuit. The labels are placed in the middle of the biscuit so the record can stay cool while it is being pressed.
The biscuit moves forward to the press, where 2,000 psi is applied at high temperatures. Next, the record is cooled and trimmed of any excess vinyl. Finally, the vinyl is stacked on a spinner and is ready for quality control. After the records are approved, they are placed into individual sleeves and are ready to be shipped out.