DVD Replication: How is a CD or DVD Replicated or Pressed?

Replicating CDs or DVDs is the best way to manufacture larger quantities of discs and is the standard way of mass-producing both types of products. Duplication (or burning discs) follows a different process and is commonly used for shorter-run production runs. Read the Article at PacificDisc.com DVD duplication vs. replication for a better explanation.

Replicated discs (typically 500 or more units) are manufactured following these 6 steps:

Step One - The DVD Glass Master. First, a precise copy of the source material, called a glass master is made. A glass disc is coated with a thin layer of light-reactive material. A laser etches pits representing 1s and 0s into this layer, to create a DVD master version of the CD or DVD.

Step Two - The Stampers. The glass DVD master is too fragile to be used directly in the replication process. Instead, it acts as a mold to create several more durable metal stampers, which are then attached to injection molding machines.

Step Three - Molding. Transparent plastic, called poly carbonate, is injected into a mold that has the stamper on one side and a smooth surface on the other. The stamper side of the mold imprints data pits into the plastic.

Step Four - Reflective Material. The poly carbonate material is transparent, so even though the data pits have been imprinted, a layer of reflective material must be applied behind them so that a laser can read them. A thin layer of metal, usually aluminum, is applied to the back side of the disc to create the necessary reflective surface.

Step Five - Lacquering. The reflective layer is then protected with a coat of acrylic lacquer, which is cured by ultraviolet light.

Step Six - Labeling. A DVD face label is silk-screened onto the cured lacquer in inks cured by ultraviolet light to create the finished product. Check out our DVD labeling and DVD artwork options for more details.