The CD/DVD Manufacturing Process

The process of CD/DVD manufacturing has revolutionized the way the world enjoys its entertainment audibly and visually. Before the onset of CD/DVD mass-production, more prehistoric methods, such as vinyl records, 8-track, cassette and VHS tapes were used to mass-produce music albums and movies. Now, with the introduction of CD/DVD manufacturing, we take a step into the modern world. Instead of purchasing bulky vinyl or poorly made tapes, music and movie lovers can enjoy their entertainment in the form of a small, shiny, futuristic disc that can be played in the car or in the home. How did the mass-production of CDs and DVDs become such a driving force in the world of media? What was the integral, small step that allowed us to take the giant leap into manufacturing CDs and DVDs in bulk, and in the process changed forever the way in which the world views its entertainment?

For those wanting the answer to these fascinating questions, the first point that needs to be understood is the fact that CD/DVD manufacturing is a complex process. Extraordinary chemical processes combined with intricate and time-consuming procedures are the ingredients that make up the formation of a disc. However, it is consequential to understand, when investigating the progression of CD/DVD technology, the process of replication. Many steps take place in the manufacturing of discs: glass mastering, photoresist or non-photoresist mastering, post mastering, and electroforming. Yet the most crucial step in this process is known as replication.

Replication of CDs and DVDs is the step that takes place after the quality of the glass master has been determined to be ready for large-scale production. This is the critical point in the manufacturing process. It is the point in which the album creates a super-star out of a singer. CD and DVD replication has made it possible for listeners from Tokyo to New York and everywhere in between to have access to the same discs. It is a process that has truly revolutionized the fashion in which the world listens to music and sees movies.

What exactly goes into the replication process? It involves a few steps, each of which must be understood to learn how replication works. Replication begins in a factory with a CD molding machine. This machine uses exceedingly high-temperature polycarbonate injectors. Hot molten plastic is inserted into the mold cavities forming a disc. Each molding can produce 900 discs per hour! Cool water is then run so that it gathers around the molding, solidifying the plastic and the molding is then opened. This entire process takes just three to five seconds.

After molding is complete, a vacuum handler removes the disc and places it onto a cooling station. The disc actually contains all of its digital information at this point in the process. However, it doesn’t have its reflective layer yet. The reflective layer is what ensures the disc can be played. After it is cooled, the disc passes into a chamber and undergoes the “sputtering” process. During this phase, metal is coated onto the data side of the disc (the side which does not have the record label).

Next, lacquer is coated onto the metal layer providing a surface for printing the DVD or record label. The printing ink must be compatible with the lacquer. If not, the disc may fracture and become ruined. This is also true for CD and DVD owners. Pens used to write on discs must be compatible for the same reason. This completes the replication process.

Thus, the process of replication is complete. The replication process has been revolutionary in ensuring the mass-production of CDs and DVDs. It has literally changed the way in which millions of music and movie lovers enjoy their entertainment. Next time you’re in the music aisle of your favorite store or at the local video shop, take a moment to think about the process of replication. It has truly been instrumental in making CD/DVD manufacturing a leading force in the world.