between CD DVD Duplication and CD DVD
Replication tends to cause confusion with
clients. While the end result may not seem to be
noticeable or of any consequence, the processes and
the final product are actually very different.
The difference is
important to know when you're preparing a project,
because the difference between CD DVD Duplication
and CD DVD Replication affects price, the product
turn-time and the quality.
In short, replication
is a manufacturing process that creates CD and DVD
discs from scratch with the data being integral to
the discs when they are made. This is much different
to duplication which uses pre-manufactured
CDR and DVDR discs (the "R" stands for "recordable")
that have the data content added to the disc after the
Benefits of CD DVD Replication
Higher quality data
image than CD duplication or DVD duplication.
More resilient and
greater durability than duplicated discs.
No playback issues.
in larger quantities.
Perceived as the
standard for professional quality by consumers.
This video features our DVD5 replication line in
Glass Master and Stamper
The first step in the
replication process is creation of the 'stamper'.
While this process is highly specialized and
technical, the following explanation is intended to
be very basic.
A piece of highly
polished glass is laser-etched with the digital
data from the client's content master.
Note: The data from the
client's content master is not altered or changed
in any way, it's strictly a transfer of data.
creates pits and lands in the glass in a tightly
grouped spiral pattern emanating from the center
and progressing outwards.
The Glass Master is
then metalized, but it is far too fragile to be
used to replicate discs so the data must now be
transferred to another material that is resilient
enough to handle the replication process.
The metalized Glass
Master is electroformed with nickel to produce a
"father" master which is a 'negative'
image as it
has bumps instead of pits.
The father master
is then electroformed with nickel to produce
"mother" masters which are used as 'stampers' in
the injection molding process.
Now that the 'stamper'
has been made the replication of the CDs or DVDs can
begin. Again, the process is highly specialized and
technical, so the following explanation is intended
to be basic.
Optical grade clear
polycarbonate pellets are fed into an
injection-molder which creates a clear CD/DVD disc
in its finished size and shape.
During the creation
of the clear disc, the injection-mold forces the
molten polycarbonate up against the 'stamper'
which embeds the pits and lands into the clear
process using robotic arms with vacuum suction
cups transfer the clear discs onto a conveyor line
where they cool.
The conveyor line
carries the clear discs to be 'metalized' with a
very thin layer of reflective aluminum (the laser
light from your CD/DVD player reflects off the
aluminum layer to read the pits and lands that
were embedded into the plastic in the
replication, after being
metalized the disc is placed in a spin-coater which
spreads a UV curable clear lacquer evenly across
the newly metalized layer.
Not only does the
lacquer protect the metalized layer but it also
provides a good surface for the printing of the
disc graphics by either Silkscreen printing or
CMYK Offset printing.
replication, instead of having a clear lacquer
coat, an additional clear DVD disc is adhered on
top of the metalized layer with a bonding agent.
This additional clear disc provides the surface
for the printing of the disc graphics.
To cure the lacquer
(or bonding agent) the disc is automatically placed under a high
intensity Xenon lamp.
After the lacquer (or
bonding agent) has passed through the curing station
the discs are automatically unloaded from the
replication line and stacked on spindles with a
count of 150 discs per spindle.
From there the discs
are taken to the CD DVD disc printing department.