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.