Originally posted by: Philippine Mango
No I've actually heard of things like this and manufacturers do this intentionally! Though this software thing is simply screwing up the partitions and there is no real benifit, there are such things as unused space in that way (not using a particular side of a platter).
Actually, you don't mean "unused", you mean "unusable". Small difference there.

Whether one side of a platter is either: 1) too defective to make effective use of, or 2) remains "unfinished", in order to save on costs, in either case you cannot somehow convince the HD to use that "extra space", since the platter isn't finished, and even if it was, there is no factory-recorded low-level servo information. Remember, you can't low-level format IDE drives in the field.
You're more-or-less right about some drives not making use of both sides of a platter, but the numbers are slightly off. Current 160GB HDs, use two platters, each 80GB in size, which implies 40GB/side. So newer 120GB HDs, are generally 160GB drives that didn't make the grade, and have only three finished platter sides to them. Older 120GB HDs used 60GB platters, so there were two platters, each with two 30GB sides. Generally, higher density per platter is better, because it implies a higher linear media-transfer rate, and thus a higher continuous data-transfer rate from the drive to the host. (So the newer 3-sided, 80GB/platter 120GB HD, would likely be faster than the older 4-sided, 60GB/platter 120GB HD.)
Few consumer-level IDE HDs ever used more than three platters per spindle; one of the few that did was the ill-fated IBM 75GXP family, and recent IBM, Maxtor and Seagate drives have reached back up to four platters/spindle. (At 100GB/platter, that gives a max size of 400GB per drive.) Prior generation drives generally were one, two or three platters/spindle, like Maxtor's DM+9 and WD's "JB" Caviar Special-Edition drives.
Originally posted by: Philippine Mango
In some cases, HDD manufacturers can get SO lazy that they will leave all 5 platters in a drive but only sell a particular capacity because it's simply easier.
That's about the only thing that's
not true - unlike CPUs, that come off of the same assembly-line, and cost the same amount to make, regardless of final speed grade (well, testing costs may vary a tiny bit) - HDs have a mfg cost that differs depending on the number of platters in the drive, and HD mfg's operate on such slim profit margins, it would be financial suicide to intentionally leave good platters in a HD, unused.
Originally posted by: Philippine Mango
In theory the HDD manufacturers will also use platters where one side is damaged in drives that only need an odd number of sides.
Yes, that's true.