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.