How are Vinyl Records Made?

In an era defined by digital streaming it's perhaps surprising that the appeal of analogue vinyl is actually increasing. But have you ever wondered how these iconic (usually) black plastic discs are actually made? Join us as we venture into the arcane world of vinyl record manufacture.

We’ll also explain other aspects of the vinyl revival, such as the potential impact on the environment that vinyl manufacturing has and the steps that Breed are taking to mitigate the impact.

The viny record making process

Step 1: Cutting a vinyl record.

The cut is a fundamental part of making a vinyl record and is as much an artform as it is a technical process requiring specialist sound engineers to manage it. The cutting engineer needs an understanding of how different styles of music with their particular dynamic range and frequencies require subtle differences to the audio processing to achieve the best sound quality possible.

The audio master is cut to either a lacquer (nitrocellulose coated aluminium) disc or direct to copper plates (DMM) using a special lathe which looks like an oversized record player and works in a similar way but in reverse. The audio is converted to mechanical motion via stereo cutting heads comprised of two moving coils perpendicular to each other - one for the left and one for the right channel. The cutting stylus cuts a precise, V shaped, spiral groove across the plate spinning at an exact speed of 33⅓ or 45 rpm. The discs themselves are 14", 12" or 10" in diameter which correspond to 12", 10" or 7" of the finished record.

Step 2: Processing lacquers and coppers

Once the cut is complete it's time to process the lacquers which are first washed with demineralised water, degreased and chemically activated in a bath after which they can be sprayed with silver nitrate,  a process called silvering.  The silvered master disc is then immersed in a tank containing nickel solution using an electroplating process to create a negative which is known as the father. The original lacquer is frequently damaged when it is removed from the father which then becomes a master which can be used multiple times.

A second ectroplating process results in a mother which is effectively a metal duplicate of the original lacquer which can be played like a record to check the process as been succesful. A this stage the mother is similar to a DMM copper and ready to move to the next stage of the process.

Step 3: Creating the Stamper

The DMM copper or the mother (made from the lacquer) goes through one final electroplating process to create unformed stampers which are essentially a negative mould and these are the actual metal plates that will be used to press the vinyl records. There is still a little more work to do: the stampers are thoroughly cleaned and the reverse side polished so it is uniformly flat, the centre of the disc is precisely calculated relative to the spiral groove and the plate is trimmed to size.

Step 4: Label Production

Labels play an essential role in vinyl records where both sides of the record have a playing surface and they generally providing information about the record's tracklisting and showcase themed artwork. 

The labels are printed on large rolls or sheets before die-cutting into their distinctive circular shape. These labels are then baked to remove any moisture, which is vital as steam produced by the moisture will wreck the pressing process. These circular labels are later applied to the vinyl records during the pressing stage.

Step 5: Pressing the Record

To begin the pressing process, vinyl pellets, made from polyvinyl chloride (PVC) are melted and shaped into small pucks each consisting of just enough vinyl for one record. The stampers are attached to the hydraulic vinyl press ready for pressing. For each record, a puck is placed in the centre of the press sandwiched between the two labels. The press then applies intense pressure and heat which forms the vinyl material into the familiar record shape applying the grooves of the stamper. The labels fuse with the vinyl during this process, creating a seamless bond. The records are trimmed to remove the rough edge and as the vinyl cools, it solidifies to form a completed record.

A sample record will undergo quality control checks both visually, under a microscope and on a record player to ensure audio fidelity and then go on to be packed into sleeves ready for despatch.

The final word

The vinyl process takes a lot of precision and patience to produce, but there’s no doubt that the final product is worth the effort. As timeless pieces of musical heritage, vinyl records continue to prove popular with music lovers across the globe.