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When you look at the sensitivity of a microphone on its spec sheet, you will find a nominal value and a tolerance
of that stated value. As an example, sensitivity specifies the output of a microphone when in a 94 dB SPL. On
the spec sheet, it may look something like this:
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In any production, including the manufacturing of microphones, the product is designed to comply with specific
predefined measures – nominal values. These measures can be related to anything measurable: dimensions,
color, electric performance, and so on.
To pass production control, the measures of the produced element must be within specific limits. For example, if
a microphone capsule's housing is mechanically off-target, it may not fit the preamp. Likewise, individual
microphones will sound and perform differently if sensitivity and frequency response don't comply with specific
limits.
Tolerances in production
In any production, deviations from target values occur. This is true whether it is mechanical measures, electrical
measures or any other. Absolute precision is preferred; however, it does not exist. That is why tolerances are
introduced. Even when focus is placed on delivering consistent quality, a microphone still undergoes many
processes during manufacturing, and each of these has a nominal value and a tolerance.
For each process, there can be one of three outcomes: spot on nominal value, too low or too high. However, in
real life, it is most likely to be either two too low or too high.
The sum of all the subprocesses of microphone production (or any type of production) can be shown in a
triangle, illustrating the output of each of the subprocesses. In this way, we can visualize that there are
substantially different paths for which an individual microphone can end up in its final shape.
Figure 1. Illustrates how individual process passes can lead to multiple outcomes. At the top, there are only two
outcomes, but moving downwards, many possible paths are possible. As an example, manufacturing a 5 mm
miniature microphone takes more than 100 subprocesses and consists of many materials and components that
each comes with a nominal value and a tolerance.
Processes and materials can be tweaked to give a higher likelihood for the wanted outcome, but it is impossible
to get the exact same values each time. Therefore, manufacturers specify a nominal value with a tolerance band
around it.
Tolerances in measuring
Tolerances do not only apply to manufacturing but also the measurement of a product. Measurement tolerance
relates both to the precision of the measurement technique itself and the measured data's read-out. Usually,
numbers are rounded, providing a value sufficiently precise to describe the result.
Fig. 2 shows a professional acoustic calibrator for measurement microphones. This device provides a very
accurate sound level @94 dB SPL (1 Pa) which is known as the reference value. (This shown unit can also
output +20 dB more.) It is regarded as a high-precision calibrator, the best in its class. However, the specs of this
calibrator show an accuracy of ±0.2 dB.
Further, the output level reading device may exhibit similar accuracy.
These tolerances add up when presented on the spec sheet. See figure 3 for the summation of tolerances.
Selection. You produce the best you can, but the sensitivity values can vary widely. You then select the units
which fall inside the decided tolerances. The blue curve in the diagram below shows the principle of distribution
of data within limits based on this methodology.
Precision. You are more precise and aim for the target value during the production process. Tolerances still exist.
However, the number of units close to the tolerance limits is clearly diminished. Most microphones are either on
target or very close to the target, even though the tolerances applied are the same as the "selection method".
Figure 4. The outcome of two different production strategies. The blue curve shows the production yield based
on selecting within limits. The red curve shows the yield when controlling the production process. More units are
closer to the nominal value (the green line) in the latter case, the method applied by DPA.
It is less critical (or doesn't really matter at all) if you only have one microphone, as you usually compensate for
the absolute sensitivity by adjusting the gain setting.
Conclusion
Any mic you purchase from DPA has been thoroughly tested to meet extremely tight sensitivity tolerances. The
6060 Series Subminiature Lavalier has sensitivity tolerances that are even tighter (± 2.4 dB, i.e. ±1.9 dB
production tolerances) than the 4060 Series Omnidirectional Miniature. You can count on DPA to deliver mics
that offer consistent sound as well as sensitivities.
2 0 2 8 Vo c a l M i c
The 6066 mics sport a completely redesigned, lightweight, one-size-fits-all headset that attaches
over the ears for maximum comfort.
6 0 6 0 & 6 0 6 1 L AVA L I E R
What they lack in size, they more than make up for in clarity, consistency and durability – three
qualities that really matter.
DPA Microphones A/S
Gydevang 42-44
DK-3450 Alleroed
Denmark
Tel. +45 4814 2828