CD Replication & DVD Replication, Production and Manufacture

At Indigo we can offer replication for all formats of CD and DVD. This includes, audio CD, data CD, mixed mode CDs, (both audio and data/video), and video CDs. For DVDs the formats available are DVD audio and DVD video and the capacities available are DVD-5, DVD-9, DVD-11 and DVD-18.

About the replication process

Disc replication is also known as pressing. This is the ideal method to use for manufacturing discs. The minimum quantity that can be ordered of CD and DVD replication is 500 or more. CDs and DVDs manufactured using replication are considered to be more reliable when it comes to playing the discs on different systems and platforms. This can vary from home computers, to in-car entertainment units and home DVD entertainment systems. Although this is less of a problem these days with better quality players, and better quality blank media.

The biggest physical differences between duplicated discs and replicated CDs and DVDs are on the bottom side. Replicated CDs and DVDs usually have a silver dye finish, whilst the duplicated counterparts have a greenish tinge for CDs and a purple one for DVDs.

Manufacturing process

There are several stages involved in the manufacture of replicated or pressed discs. The source material can be supplied in a variety of formats. The first stage is known as premastering where the source data is readied and prepared. The next stage is known as mastering, or glass-mastering. This is where the data is imaged on to a round glass disc. This disc now contains all the data that has to be replicated and this glass-master is used in the electroplating stage where the data is transferred to a metal plate or stamper.
This stamper is used for the actual pressing of the CD or DVD copies through an injection moulding process. Polycarbonate powder is pumped into the machinery, heated up to melting point and then this is pressed and imprinted with the information contained on the stamper.

When the injection moulding and disc pressing process has completed we are left with a clear circular plastic disc. These discs then move on to the next process called metallization. At this stage of the process, the disc is coated on one side with a thin layer of metallic film. Following this the disc is then applied a layer of lacquer which seals in the metallization, this is known as spin coating.

After this, the discs are actually ready to be used. However, most replicated discs have a print to go on the top side, and the final process is that of printing onto the top of the disc. This can be either an offset printing process or a screen-printing process.

Packaging options

There is a range of packaging available for CD replication and DVD replication.
Find out more on CD Duplication, CD Copying and CD Production.
Find our more on DVD Duplication and DVD Production.

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