The process of manufacturing CDs and DVDs has changed the way in which the world looks at and listens to entertainment. Prior to the introduction of CD/DVD mass-production, less sophisticated means, such as vinyl records, tapes and VHS were used to mass-produce music and movies. But now, with the revolution of CD and DVD manufacturing, we take a step up. Music and movie fans no longer have to purchase bulky records or poorly manufactured tapes in order to listen to music or enjoy their favorite movies. With the birth of the compact disc, anyone can easily slip this small, shiny circle into their car stereo or home entertainment center for their listening and/or viewing pleasure. But how did the mass-production of CDs and DVDs become such a powerful force in the world? What was the indispensable step that made the manufacturing of CDs and DVDs possible, and in the process shaped a new mold for the way the world enjoys its entertainment?
Those interested in getting answers to these evolutionary questions, need first to understand that CD/DVD manufacturing is an intricate process. Complex and time-consuming procedures along with amazing chemical processes combine to produce the formation of a disc. It is crucial to understand, when examining the advancement of CD/DVD technology, the process of replication. Many steps are taken to manufacture discs: glass mastering, photoresist or non-photoresist mastering, post mastering, and electroforming. But the most vital step in the process of manufacturing is 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).
After metallization, lacquer is coated onto the metal layer. This provides the right surface for the DVD or record label to be printed. It is crucial that the ink used in printing the label is compatible with the lacquer coating. It is also important for people to remember the necessity of ink being compatible when using a pen to write on a CD or DVD as the disc might fracture and be ruined if it’s not.
And, presto! The process of replication is complete. Replication has opened the door for the mass-production of CDs and DVDs and in the process, changed the way the world enjoys music and movies. Take a minute to think about that the next time you head out to the video store to pick up the latest DVD release or when rummaging through titles on the CD aisle of your favorite shop. Replication has allowed CD and DVD manufacturing to become a prominent force in the world.
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