3D printing a record might seem like the obvious choice these days, but I decided to go with CNC milling.
Why a mill you ask? Not a laser cutter or a 3D printer? Well we can't use a laser cutter as the record needs slots in the surface but these don't go all the way through. Laser cutters are great if you don't need any partial depth cuts, but we do. 3D printing the record would seem to be a sensible choice and would definitely do the job. However, we will end up creating plastic pins around 1mm in size that trigger the music box hidden in the record player's arm. I was worried about whether the extruded plastic technique used by most printers would give it the required strength. That, and I don't have a 3D printer.
Also the CNC mill means I'm not limited to plastic. I can just as easily create the records from wood (a hardwood should be strong enough) or even metal, but let's start with plastic.
If you want to 3D print a record then my code will have to be adapted but it's all open and should be easy enough to convert. If I get a 3D printer then I'll definitely adapt the gcode generation part so that it can create the appropriate files for a printer. I'll be entering this in the "Make it Real" challenge, so you never know... In fact, if I win a 3D printer, I promise I'll update it so it can print records too. Anyway, what could sum up "Make it Real" more than taking something intangible like music and turning it into something physical.
UPDATE: I've now finished a 3D printed version of this project. As all but one of the steps are different, I've created a separate Instructable for it here. So if you don't have a CNC mill (that's everyone apart from rdarlington) then you can now create your own discs.
Continuing the spirit of Instructables, if you create the music and share it, I'll make it real for you. Download the music editor (see step 3) and send me the fpr file it creates. I'll pick the best, mill them and a send out some discs. I'm not very musical, so sure that it won't be hard do do better than my attempt. I have to limit it to 5 just because each one will take me a couple of hours to do.
Step 1: What you'll need
Firstly, you'll need a CNC controlled mill or router with a 1mm end mill. I understand that this is not exactly the sort of thing most people have lying around - but it should be! I bought a mill and converted for about £525 (€650 or $825) and it's been so useful for milling PCBs and creating random stuff like this.
If you're interested I've detailed my conversion in another Instructable here. Plenty of other people have documented their builds of this and similar mills too.
Secondly, you'll need a suitable sheet of plastic to mill. I used acrylic sheet in either 3mm (for single-sided record) or 5mm for a double-sided one. This easily available in A4 sheets that is enough to create 2 records. Another advantage of the mill is that we could make our records out of wood or even metal. Let's stick to acrylic for now though.