Microphones are the most reliable and competent way to produce audio and are highly trusted by engineers. No matter from which field you belong, if you are a producer, vlogger, content creator, broadcaster, journalist, teacher, singer, or student, you have to use the microphones in any way at least once in your whole life.
But a question always pops up in the users’ minds how microphones are made? And this is one of the most genuine and authentic questions that should be answered. Different manufacturers have different ways to produce microphones depending on the type of microphone they want to produce.
So if you are also curious to know about the production of a microphone, then go ahead without further delays and read with us! Although this is hard to sum up in this article because of the many types of microphones, we will try to explain the basics of production.
Okay, let’s go!
Background and History of a Microphone
The first microphone was invented as a liquid microphone device in 1876 by the great Alexander Graham Bell. But the people were so unsatisfied due to the impracticality, and then Thomas Edison introduced the world with the carbon microphone after a decade after it invented the first microphone. This carbon microphone was the most important and practical component of radio transmissions. But the drawback of this microphone was its low-frequency range.
In 1916, E.C Wente invented the first condenser microphone, which was one of the most practical solutions to the previous two problems. These microphones were then used for radio broadcasting with the most effective and fine sound quality.
Another great introduction to the world of microphones was done by Wente and A. C. Thuras in the year 1931. This invention was the greatest of all the previous inventions as it was a dynamic microphone. This microphone was no longer dependent on the power supply and presented reduced noise levels. In the same year, another type of microphone, the ribbon microphone, was invented, but these were the heaviest microphones.
Now have a look at the background!
Microphones are devices that are specially manufactured to transfer mechanical sound energy into electrical sound waves through a specific mechanism. Microphones are a major part of everyday life as they are the main component of radio, telephones, recorders, monitors, and television. They have several different types, including dynamic and ribbon microphones, that vary in their working and design.
The Main Components of a Microphone
Before getting insight into the detailed design and production of a microphone, we should know the main components of a microphone. The name of components that make up all types of microphone includes the diaphragm, which is the main element of a microphone, the capsule, and the internal wiring system.
The diaphragm is a thin membrane that moves according to the sound frequency that strikes its surface. It depicts the sound waves and responds according to them that later create an audio signal.
The capsule or the cartridge of a microphone is the casing or the housing of the diaphragm. This housing, or the so-called baffle, allows energy conversion, i.e., mechanical energy into electrical energy. Specifically, for the moving coil dynamic microphones, the circular diaphragm is housed in the cartridge.
The internal wiring is mandatory for the current supply.
The Manufacturing Process of a Microphone
A moving coil or the dynamic microphone is the most durable of all the microphones, and it has many applications due to no power supply.
Let’s discuss the manufacturing process in detail!
Firstly, the case of the microphone is manufactured. This manufacturing requires either plastic or thin aluminium sheet. This sheet is then put into the die of a hydraulic punch press which exerts pressure and helps in discarding the extra material.
But what happens if the case is to be made with plastic? The plastic is melted and then poured into the molding machine. After the cooling of the plastic is done, then the mold is opened, and the plastic case is taken out.
After the casing formation, the voice coil is made with the help of enameled copper wires. These fine wires are winded on a plastic bobbin, and then connections are fixed with glue.
In the third step, the permanent magnet is manufactured by using a compound known as neodymium iron boron, an exotic material.
After that, the already cut plastic diaphragm is placed in a fixture to hold, and the connection of the voice coil through glue is secured. To make the connection stronger, the diaphragm is placed for about 24 hours for complete drying. Once the connections become permanent, the whole assembly is then attached to the permanent magnet by applying glue in the same way as described above.
A coaxial audio cable is required here to cut into a certain length with the one end of the cable remaining opened, which is used to insert into the bottom of the case of the microphone and then pulled out through the top to allow the internal wiring to reach the switch and the voice coil.
For the secure assembly, the voice coil assembly is surrounded by the foam rubber spacer and then secured by using a cap and grille.
The process is done!
Most amazingly, this hectic process has a very great fruit in the end as raw materials like plastic or metal could be recycled for further use. And the neodymium iron boron can be disposed of safely.
Last Statement
Microphones are the most useful invention, and engineers are still experimenting with them and are constantly being redesigned to customize the needs and demands of the users. Hopefully, this guide has helped you to know all about the production of microphones, and you have no questions left in your mind!
William Souza Here, I Am Sound Specialist, Have Trained Many Musicians And Singers. I Write Blog Contents About Sound, Music, Microphone Reviews, Speaker Reviews, Sound Card Reviews And All About Sound/Music Reviews And Instruction. I Am Writing On This Blog MicrophoneGuides.com As On My Experience And Will Update More Information & Review About Different Microphones For Different Users.
