Replication

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The replication process is a precision closed-loop injection moulding process which impresses polycarbonate onto stamper to produce a clear data substrate. DVD replication involves 2 separated layers of injected substrate formed by 2 injection molding machines. A micro thin layer of aluminium (aluminium and silver for separate substrate in DVD9) film is deposited onto the clear substrate to act as a reflective layer for laser read back. An adhesive (bonder) will bond both sides together into a single disc. Each individual disc is then screened for any visual defects.  

There are 2 common types of DVD, i.e. DVD5 and DVD9:

  • DVD5 is made out of a single layer where information can be stored. Only the information layer is sputtered with aluminum & the dummy layer is not.
  • DVD 9 is a single sided dual layer DVD that allows data from both layers to read  from one side. As a result DVD 9 can store twice the amount of information as DVD5. Its bottom substrate is coated with semi-reflective gold, silver or silicon alloy and the top substrate is sputtered with aluminum. This allows the laser to read data content from both substrates by adjusting the focus point. They are then bonded together by way of squeezing the discs together so that both information layers are facing each other.
  • We provide DVD Replication services in Multiple Formats:

  • DVD Video 5/9/10

 

How to store content information into a disc?

There are generally 2 ways of doing this

(i) disc duplication

(ii) disc replication.

Disc duplication is simply a basic copy process of burning data into photochemical layer of the CD-R or DVD-R recordable disc.

Disc replication is a precision closed-loop injection moulding process which impresses polycarbonate onto stamper to produce a clear data substrate. DVD replication involves 2 separated layers of injected substrate formed by 2 injection moulding machines. A micro thin layer of aluminium (aluminium and silver for separate substrate in DVD9) film is deposited onto the clear substrate to act as reflective layer for laser read back. An adhesive (bonder) will bond both sides together into a single disc.

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