RECORD MAKING PROCESS

A lacquer is an aluminum-based disc, covered with a plastic material that is cut from master tapes. Each lacquer is single sided so two must be produced for a regular two-sided record. MASTERCRAFT METAL FINISHING performs the following electroplating processes.

The lacquer (MASTER DISC) is put through a process called Galvanic Electro Formation. First the lacquer is meticulously cleaned in a mild detergent-based solution, rinsed with high purity DI water and sensitized in a Stannous Chloride solution. The lacquer is then placed on a spindle in a Silvering Booth. There the lacquer is mechanically spun at a carefully modulated speed and sprayed with a Silver solution to make the surface electro-conductive.

The Silvered lacquer is placed in a pre-plate electroforming tank and is plated with Nickel at low amperage/temperature. The Nickel will naturally adhere to the Silver on the lacquer surface. The lacquer stays briefly in the pre-plate tank. It is then transferred to a high-speed electroforming tank and is plated with Nickel at greater amperage/high temperature to produce a metal Master Plate (FATHER).

The FATHER plate is separated from the lacquer, creating an exact reverse image, with outwardly protruding ridges instead of etched grooves. The FATHER plate is cleaned, chemically passivated and transferred to another electroforming tank and plated with Nickel to produce a metal MOTHER plate.

The MOTHER is a positive metal plate identical to the MASTER DISC. The mother plate is separated from the FATHER plate. The MOTHER plate can be played on a turntable to check for errors in mastering or plating.

The MOTHER plate is passivated and placed in an electroforming tank and plated with Nickel to create a metal STAMPER. The STAMPER edges are then trimmed and the reverse side is polished. The STAMPER is optically centered and a hole is accurately punched. It is then mechanically formed to fit the record press mold block. The STAMPER is a negative image and is used to press records.

1-Step Process: The metal Master Plate is mechanically formed and is used to press records. It is referred as a one-step MASTER STAMPER, which can produce about 500 vinyl records. The lacquer is usually good for one STAMPER.

2-Step Process: The lacquer is coated with Silver and Nickel electroformed to make a STAMPER. In the second step the STAMPER is Nickel electroformed to create a MOTHER. The MOTHER is stored for future use to create replacement STAMPERS.

3-Step Process: The lacquer is coated with Silver and Nickel electroformed until desired thickness to create a metal Master Plate (FATHER). The FATHER is used to make a MOTHER. The MOTHER is then used to make STAMPERS.

One FATHER plate can produce ten (10) MOTHER plates. One MOTHER plate can produce ten (10) STAMPERS. One STAMPER can produce about 1,000 vinyl records. Therefore, a two-step process can produce a maximum of about 11,000 vinyl records before a remastering has to be done. A three-step process can produce up to about 100,000 vinyl records before remastering.

Copyright © 2007 Mastercraft Metal Finishing, Inc.   All Rights Reserved.                                                                                                         Date This Page Was Last Updated     March 19, 2007