Replication Process

Replication Process

1: Pre-Mastering

In this stage Abet Disc inspects the format and structure of the media that is supplied by the customer.

Step 2: Mastering

A substrate treated with a photosensitive layer is prepared.
An LBR (Laser Beam Recorder) is used to transfer your data/music and forms the pits and tracks onto the substrate.
A developing solution enables the zones that were exposed by the laser to be removed.
The substrate is placed into a vacuum deposition chamber and covered with a layer of silver.
The end product is a metalized glass master. It is then inspected and analyzed for electrical signal properties.

Step 3: Electroplating

Glass master is mounted and immersed into a solution of nickel sulfamate.
A process of electrolysis takes place between two electrodes, the anode and the cathode. This creates a nickel layer which is separated from the glass master in order to obtain the stamper.
The stamper is rinsed, dried & covered with a protective film.
The back face is sanded and polished in order to prepare it for pressing.
The stamper is then punched in the center and the outside and checked for uniform thickness.

4: Molding

The stamper is placed in a special mold and clamped together under very high pressure. Molten polycarbonate is then injected into the mold and after a few seconds of cooling, a clear disc is ejected, now containing the information or pit track from the stamper.

A fine layer of aluminum is sputtered onto the surface of the transparent disc. This allows the disc to be read by the reflection of the laser on the layer of information.
A fine layer of clear lacquer is then deposited on the metallic surface of the disc, then dried under a UV lamp. This is done in order to protect the CD and
prepare it for screen or offset printing.

Each CD is then inspected for physical imperfections and common molding flaws using a high speed camera inspection system.
All orders are tested at the beginning and the end through the High Tech Optical Testing Equipment to Phillips and Sony specifications.

Step 5: Pre-Press

The film or file is initially reviewed by trained graphic staff and checked for conformity, colors, size, resolution, fonts etc…
Pre-stretched screens are coated with a light sensitive emulsion, dried and measured.
Once dried, a film positive is positioned upon the coated screen and exposed in a light unit for a set time.
After exposure, the developed emulsion protected by the film is washed away with water. This leaves a hardened stencil with print area free of exposed emulsion.

Step 6: Screen Printing

Press-ready screens are mounted on the printing press.
Ink is placed on the screen and a squeegee passes across the image area pressing ink through the screen and onto the CD surface. One screen is required for each color.
Once the ink is applied, it is instantly cured or dried under a UV light before the next color is printed.
Each CD is inspected through sophisticated optics for correct inner hub identification and print quality.

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