The Blu-ray replication process begins with a polycarbonate substrate mould containing data that is made up of the pits and lands.This is followed by sputtering the reflective layer, then applying a base spacer layer which ahered ready for the pit transfer layer

After the moulding process, the Layer 1 data layer is embossed before another reflective layer is sputtered.  The UV-cured resin cover layer is applied after which another hard coat layer is applied. This is necessary because the Blu-ray disc data layer is closer to the surface and more vulnerable to scratches. Finally the metalised moisture barrier layer is applied to prevent warping of the disc.

Our services include BD25 and BD50 replication with 5C offset printing that are bulk packed in spindles.