DVD Replication Process

Replication is the process that transfers the data from the source master to CD or DVD discs. It’s often talked about with ‘Duplication’, and it is a common misconception that they are the same. Here we’ll try to reveal the mystery behind replication.

Replication means copy that is not the original; something that has been copied OR the act of making copies. When it comes to DVD Replication, so it refers to the process of ‘pressing’ copies of a DVD glass master onto aluminium/polymer blank discs. Replication is the process that transfers the data from the source master to CD or DVD discs. It’s often talked about with ‘Duplication’, and it is a common misconception that they are the same. DVD replication is a very different process than duplication, though, which is the same type of process that you use with the CD burner on your personal computer. Here we’ll try to reveal the mystery behind replication

The results of DVD replication do not normally vary, as much of the DVD replication equipment used is standard throughout the industry. DVD replication companies and brokers are the only ones who can do the job for you. They usually also offer silkscreen or offset printing onto the DVD surface as well as printing and packaging. Some will even offer customised shapes (e.g. star shapes, oval DVDs), and mini (8cm) DVDs.

DVD replication gives you simple duplicates of your master DVD that will play on all DVD players and computers. The DVD can be printed on the label side and will be silver on the data side unless a special colour has been chosen.

Pre-requisites of DVD Replication Process

After the source master is submitted to the manufacturing plant, it is first checked for unreadable sectors. It could be the result of an incomplete DVD-R or CD-R. Without this verification steps you might end up with many faulty discs at the end. Before the DVD Replication Process being started, we have to check following things;

DVD Duplication: Its in fact burning of DVDs. Duplication is a process where lasers “burn” pits into a dye that is manufactured inside the disc. Burning is the process used by the drives in virtually every home or work computer used today.

Glass Mastering: When we talk about ‘pressing’ discs, the first step is to transfer data from the master onto a ‘master mold’. In this case it is called a glass master.

Stampers: You must heard of it before, but what is a stamper anyway? The glass master is used to create a stamper – the mold for the CD/DVD discs.

Molding the discs: With the stampers that are created, we’re ready to mold the discs. Polycarbonate materials are molded with the grooves on the stampers to become a disc.

At the beginning of the DVD replication process, which is typically done in industrial settings or manufacturing plants, the source disc is checked for any unreadable portions.

DVD Replication Process includes following steps

Pre-Mastering

In this stage Abet Disc inspects the format and structure of the media that is supplied by the customer.

Mastering

DVD mastering is a digital optimization process that readies a DVD project for replication or duplication. Commonly packaged with related services such as label and sleeve printing, DVD mastering encompasses both audio and audiovisual work.

A substrate treated with a photosensitive layer is prepared. An LBR (Laser Beam Recorder) is used to transfer your data/music and forms the pits and tracks onto the substrate.A developing solution enables the zones that were exposed by the laser to be removed.

The substrate is placed into a vacuum deposition chamber and covered with a layer of silver. The end product is a metalized glass master. It is then inspected and analyzed for electrical signal properties.

Electroplating

Glass master is mounted and immersed into a solution of nickel sulfamate.
A process of electrolysis takes place between two electrodes, the anode and the cathode. This creates a nickel layer which is separated from the glass master in order to obtain the stamper.

The stamper is rinsed, dried & covered with a protective film. The back face is sanded and polished in order to prepare it for pressing. The stamper is then punched in the center and the outside and checked for uniform thickness.

Molding

The stamper is placed in a special mold and clamped together under very high pressure. Molten polycarbonate is then injected into the mold and after a few seconds of cooling, a clear disc is ejected, now containing the information or pit track from the stamper.

A fine layer of aluminum is sputtered onto the surface of the transparent disc. This allows the disc to be read by the reflection of the laser on the layer of information.
A fine layer of clear lacquer is then deposited on the metallic surface of the disc, then dried under a UV lamp. This is done in order to protect the CD and
prepare it for screen or offset printing.

Pre-Press

The film or file is initially reviewed by trained graphic staff and checked for conformity, colors, size, resolution, fonts etc…

Pre-stretched screens are coated with a light sensitive emulsion, dried and measured.
Once dried, a film positive is positioned upon the coated screen and exposed in a light unit for a set time. After exposure, the developed emulsion protected by the film is washed away with water. This leaves a hardened stencil with print area free of exposed emulsion.

Screen Printing

Press-ready screens are mounted on the printing press. Ink is placed on the screen and a squeegee passes across the image area pressing ink through the screen and onto the CD surface. One screen is required for each color. Once the ink is applied, it is instantly cured or dried under a UV light before the next color is printed.

Each CD is inspected through sophisticated optics for correct inner hub identification and print quality.

The DVD replication processes require quality, accuracy and speed from start to finish. The DVD replication process involves the creation of a glass master disc from a DVD or digital linear tape . The glass master is then used to manufacture additional discs by physically imprinting (stamping) data onto their foil or plastic substrates.

Quality matters when DVD CD Replication is on tap. Whether the need is to have 20 training programs replicated for offices all over the world or a demo CD is required to launch a band into stardom, if quality suffers so does the project.