A trip to the Rycote Factory

The classic blimp-shaped microphone windscreen: It’s the most iconic image of film and video sound. Even people who are not in the business relate to this because they see it everywhere; on television news, behind-the-scenes movie productions, and when passing by a film production. That familiar shape bobbing around high overhead on a pole is difficult to not look at.

I recently had the chance to visit the source of these windscreens, the Rycote factory in Stroud, England. With transportation courtesy of one of the owners, Simon Davies, I was free to take in the countryside on the way to the factory, which is nestled in one of the most quaint and serene settings I’ve ever been. And as someone who has worked with these windscreens for 30 years, I admit that I was star-struck as the Rycote sign came into view.

Simon Davies (L) and Glen Trew (R)

There, we were greeted by Vivienne Dyer, who deserves credit for leading Rycote to their global status since 1984, and part-owner Odette Davies, who gave us the factory tour. Once inside, it was clear that the high-quality craftsmanship that Rycote products are known for is intentional, deliberate, and starts at the very beginning.

A serious office staff works at neat desks filled with computer screens, managing accounting, parts orders, production schedules, package design, and distribution around the globe. Walking through the front offices into the fabrication and assembly room reveals a working factory arranged for efficient production flow. The primary assembly area is expansive, filled with sewing benches and areas used for heating, cutting, and gluing.

Through the next wall is a large warehouse with pallets and shelves of bulk material that somehow look familiar… Stacks and stacks of plastic sheeting with a basket-weave design (soon to take the shape of the famous windshield skin); rolls and rolls of various long hair fabrics destined for different corners of the world as “Windjammers” and “Softies”.

Next are large, organized bins full of bits and pieces, that, upon closer inspection, are recognized as some of the unique parts that makeup the Rycote windshields and suspension systems: rubber O-rings, pistol grips, mic clips, mounting bars, Rycote labels, tightening knobs, etc. The next area of the building is a machining and design room used for developing new products, such as the recently introduced “Lyre” suspension. (No photos or details of this top-secret area, but suffice it to say that I saw evidence of creative minds hard at work!)

The quantities made by Rycote to fill their global demand would easily be classify as “mass production,” and sophisticated machinery is used when needed. For example, an automated “ironing machine” is used to weld the thin screen fabric to the inside of the basket frame.

The ironing conveyor welds inner and outer materials together

However, an impressive amount of the final fabrication and assembly work is hand-done by long-time Rycote employees. Cutting, sewing, forming, and gluing are seen at various workstations. It was interesting to learn that each windscreen is fully assembled by one person doing every process, instead of one person doing a single process and then passing it to another person in line for the next process. With the Rycote system, one person is responsible for the workmanship of each windscreen and suspension, which must greatly enhance quality control and product consistency, as indicated by Rycote’s reputation.

In a time where it is commonplace for companies the size of Rycote to out-source parts manufacturing to less expensive corners of the world, it is important to point out that Rycote uses local suppliers almost exclusively. They feel that this puts them in a better position to control the quality of their products, and it certainly shows.

It was great seeing the Rycote factory, meeting the people who work there, and seeing the process of making the most recognized piece of sound equipment in the film and video industry: the Rycote microphone windscreen. I learned a few things while I was there, like their suggestion of turning Windjammers inside out for storage. But even more importantly, having an inside view validated my opinion that Rycote windscreens and suspensions are designed and made with expertise by people who care very much about keeping the quality high for the people who use them.