The following excerpt is courtesy
of the Interstate DJ School DJ Training Curriculum, written and
assembled by Robert Oleysyck
How Vinyl Records
Are Manufactured
by Robert Oleysyck,
Interstate DJ School,
Las Vegas, Nevada
April
2003
Starting with a master tape,
DAT, or CD, the music is transferred to an aluminum disc covered
with lacquer, which is done using a "cutting lathe,"
Hence, the term "cutting a record." With a slightly
heated sapphire or diamond tipped stylus, the lathe etches a
spiral groove into the soft, oil based lacquer that starts from
the outer edge going in. The stylus has two coils (one
for each left and right amp channel) that are positioned between
magnets. The music master is fed into the magnets, varying the
magnetism, which in turn causes the stylus to vibrate left and
right. The stylus can oscillate at up to 16,000 times per
second. The greater the volume of the material, the wider
the groove.
This process is almost the exact
reverse of playing a record in the usual manner using a turntable,
normal stylus, and cartridge. Each lacquer disc is single
sided so two must be produced for a regular two-sided record.
Cutting is the last stage at which the sound can be altered (and
only to a limited extent). To ensure a consistent, distortion-free
transfer of the signal to the blank disc, great care must be
taken not to cut too deep, shallow, loud or quiet. If the
cut is too deep, the playback needle may not sit snugly in the
groove or reach the bottom; if it is too shallow, the needle
may skip tracks.
There is a trade off between
recording level and duration per side. Cutting at 45 RPM
offers a higher resolution, meaning that the sound is spread
over a longer length of the groove, with more space between grooves
as opposed to a 33-RPM recording. That's why a 12"
single - with one track on one side - will sound far better than
an LP with 5 tracks on one side.
In the next stage, the lacquer
disk (in some cases referred to as an acetate) is put through
a process called Galvanic Electro Formation. Through special
cleaners and agents, a metal layer of nickel and silver is formed
over the lacquer, creating a metal plate. This new plate
is a negative of the previous master, having ridges instead of
grooves, from which, several successive metal parts are produced:
The "Mother" is a positive
plate identical to the finished record that can be played and
looks like the gold discs awarded for sales.
The "Stamper" (one
for each side) is also a negative, and is then used to stamp
out or press the records. The stampers are used to "press"
the grooves into preheated polyvinyl thermoplastic discs, otherwise
known as records. With the aid of a stabilizer and lubricants,
the vinyl is fed to the press and formed into a "puck"
or "biscuit." With the labels on their appropriate
sides, the press closes, and the stampers squash down on the
biscuit to form a record. After being cooled by water,
the record is trimmed and left flat to cool. Test pressings
are usually made to check the quality of the sound and for any
flaws, which may occur.
- Contact Information:
- Robert Oleysyck
- Director - Interstate
DJ School
- 4780 West Harmon Avenue, Suite
2
- Las Vegas, NV 89103
- Phone: 702.251.7551
- Fax: 702.251.5580
New Products: The Vestax Samurai
Series Mixers: World's First Digital Crossfader
Vestax
is proud to present the new Samurai Series Mixers, the first
products to be equipped with the new Vestax Digital Cross Fader.
The Samurai Series
The revolution began at a recent
international exhibition where there was a secret Vestax product
test.
The world's top DJ's talked together
with the Vestax R&D team about the dream of a digital fader.
Everyone was "knocked out" by the new Vestax digital
fader technology that was demonstrated.
One DJ said that the crossfader's
precise cut reminded him of the sword of a Samurai, and so the
new Samurai series was born. This crossfader has the most innovative
features ever, allowing DJ's to control the fader curve digitally.
The new dawn of extreme DJ performance
begins with Samurai.
The Samurai Curve Pattern
Four types of base curve give
DJ's access to 8 crossfader curves on each Samurai selection.
32 crossfader patterns in total! Due to the magnetic field sensor
of the crossfader, Samurai series are liquid-resistant and 100%
maintenance free.
And, while we've all heard that
claim before and have been disappointed, the honorable Vestax
Samurai crossfader is 100% true to its word. Thoroughly tested
by spilling liquids and even sugar into the digital crossfader,
the Vestax Samurai fader is the only one around that under such
circumstances will really keep on playing!
The True Spirit of the Samurai
The Japanese Samurai of the 12th
Century were a fearless and powerful force of warriors, historically
revered for their code of honor and swordsmanship.
Eight and a half centuries later,
a new breed of Samurai have entered the world! Like all Vestax
innovations, the Samurai Series Mixers are both powerful, durable
and made with honor.
The range includes the PMC-05ProD,
PMC-06ProD and the PMC-07ProD.
PMC-05ProD
The PMC-05ProII is the mixer
that has been loved by so many hip-hop artists around the world.
There have been many pretenders, but the PMC-05Pro is still king.
Now, due to the addition of the new Vestax digital crossfader
with built-in curve control, the PMC-05ProD Samurai blasts off
into a new Solar System, where only the true pioneers of today's
sound will go.
* Input/Output: Phono (RCA) x2,
Line (RCA) x2, Mic (Phone)x2, Master (RCA)x2
* Dimensions & Weight: 262(W) x 103(H) x 320(D) mm; 3.5kg
* Equipped with original Vestax PCV crossfader
* Replacement Crossfader: CF-X
PMC-06ProD
The incredibly popular PMC-06Pro
now also launches into a new stratosphere with the digital crossfader.
The PMC-06ProD reincarnates the precise sword of the Samurai.
* Input/Output: Phono (RCA) x2,
Line (RCA) x2, Mic (Phone)x2, Master (RCA)x2
* Dimensions & Weight: 160(W) x 107(H) x 392(D) mm; 2.5kg
* Equipped with original Vestax PCV crossfader
* Replacement Crossfader: CF-X
PMC-07ProD
And the Battle Mixer we all love
the PMC-07Pro joins the Samurai range as the PMC-07ProD
with the slashing sound of Vestax digital crossfader technology.
Session Mix function allows team
DJ's to connect multiple mixers simultaneously.
The
Master output is TRS balanced for automatic connection to balanced
PA systems.
3-Band Slider EQ faders on each
channel with +6dB/-24dB
* Input/Output: Phono (RCA) x2,
Line (RCA) x3, Mic (Phone)x2, Master (RCA, TRS)x1
* Dimensions & Weight: 262(W) x 106(H) x 370(D) mm; 4kg
* Equipped with original Vestax PCV crossfader
* Replacement Crossfader: CF-X
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