The DVD Replication process starts from Glass Mastering similar to CD Replication
. Replicated DVD
go through a complex and arduous process as with Blu-ray or BD Replication. This applies whether ité─˘s for DVD Audio, DVD Video or DVD
Rom. Replication of Optical discs is the process for producing in large volumes, whereas DVD Duplication is for smaller runs and quick turn round.
Firstly, the customer supplies a master recorded source, this could be on CDR, DVDR, Tape, Hard Disk or data transfer along with other methods and will
depend on whether ité─˘s for DVD Replication, CD Replication or Blu-ray Replication. Pressing of the Replicated DVD discs is achieved by melting pellets of
polycarbonate in the moulding machines and pressed out using a metal stamper.
The stamper is part of a family of stampers which are produced with the aid of the glass master. The glass master itself is produced in a clean room which
must be to the highest standard of cleanliness. So before DVD Replication
or CD Replication can begin, mastering and pre-mastering have to be performed. The substrate used for the glass master is
simply a round glass plate slightly larger than a Duplicated DVD. One side is smooth and polished, the extra size makes safe handling easier and eliminates
damage to the pits and lands. Detergents and solvents are used to clean the glass master.
A solvent is used to rinse the glass master black, after which and depending on the actual mastering process used, dye polymer or photoresist is applied and
then baked. The choice of these two methods will then depend on the next process. Nevertheless, from the glass master the stampers are created for the actual
moulding of the CD Replication and Replicated DVD
The Industrial CD Replication and DVD Replication Moulding machines are high capacity and can churn out anything from 550 to 900 Duplicated CD discs per hour
per line. The Duplicated DVD or CD must then be finished. At this stage the moulded disc is known as a green disc. They have to be metallised with a
reflective layer, once complete they have a lacquer applied which is UV cured. Rigorous testing is then carried out before the Replicated DVD or Replicated
CD discs are moved to the packing process department.
The capacity of the most common DVD Replication
discs can be from a single sided and single layer 4.7 GB to a double sided single layer
9.4GB, the throughput of DVD is naturally slower than CD
. Blu-ray Replication has a different and much more complex process of Authoring and mastering. The Replication equipment for BD Disc
Replication is a huge investment for the manufacturer but with a capacity for single layer at 25GB and a double layer at 50GB, it is naturally the medium for
HD films and therefore the large film studios and will give a good return on investment as the demand continues to increase.
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