by Scott Rossi
Replication is the process of making an exact replica i.e. exact copies of your master. It's the most cost effective manufacturing process for high volume requirements for the CD Rom/ Audio - DVD Video/ DVD Rom market.
The replication process for CD and DVD consists of the following key stages:
· Glass mastering
· Stamper creation
· Injection moulding
· Disc printing
From receipt of your Master, created is a Glass Master, which is basically a piece of glass substrate from which Stampers are created. The Glass Master is placed in baths where nickel Stampers are grown on to the Glass Master through a galvanics process. The first stamper to come off the Glass Master is called the Father and from this Father Stamper, a Mother is grown and a further family of Stampers.
It's these Stampers that are used on the injection molding lines to physically press (or Stamp) your replica discs. As the discs are injection molded and Stamped, they pass down the injection molding line where each disc is individually metalized (to make it reflective) and coated with a protective lacquer, finally its UV cured and then tested for physical imperfections.
When the discs come off the line, they appear silver on both sides, so next, the artwork needs to be printed onto the disc. The two common print methods used in CD & DVD printing is the Screen printing process and the Litho printing process. The look and nature of your artwork will depend on whether the disc is Screen or Litho printed.
Replication is the process of making an exact replica i.e. exact copies of your master. It's the most cost effective manufacturing process for high volume requirements for the CD Rom/ Audio - DVD Video/ DVD Rom market.
The replication process for CD and DVD consists of the following key stages:
· Glass mastering
· Stamper creation
· Injection moulding
· Disc printing
From receipt of your Master, created is a Glass Master, which is basically a piece of glass substrate from which Stampers are created. The Glass Master is placed in baths where nickel Stampers are grown on to the Glass Master through a galvanics process. The first stamper to come off the Glass Master is called the Father and from this Father Stamper, a Mother is grown and a further family of Stampers.
It's these Stampers that are used on the injection molding lines to physically press (or Stamp) your replica discs. As the discs are injection molded and Stamped, they pass down the injection molding line where each disc is individually metalized (to make it reflective) and coated with a protective lacquer, finally its UV cured and then tested for physical imperfections.
When the discs come off the line, they appear silver on both sides, so next, the artwork needs to be printed onto the disc. The two common print methods used in CD & DVD printing is the Screen printing process and the Litho printing process. The look and nature of your artwork will depend on whether the disc is Screen or Litho printed.
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