manufacturing

DVD Replication

There has long been an ongoing debate whether DVD Duplication and DVD Replication produce the same quality results. Thought over a short period they would seem to be close to identical, over a longer period of time one beings to see the difference.

 

Replicated DVDs tend to be better equipped to withstand the test of time. Duplicated DVDs are less scratch resistant and do not do as well with temperature changes, as the replicated ones. So if you want the best possible quality for your DVD copies, then replication is the way to go!

 

DVDs have become a preferred storage medium over the past few years, due to the fact that they have a much larger storage capacity than ordinary CDs, and are also much faster at data processing. Not to mention the fact that they are a lot more durable than a conventional Compact Disc. With a DVD, you can not only sing a song, but you may also include a video that truly expresses your creative spirit.

 

Whether you are a singer, movie maker, software engineer, or a game developer,  if you need professional DVD Replication services, Abet Disc is here to help! With over 20 years of experience, we have worked with many people just like you, while helping them bring their product to market and grow their potential.

 

We have the best equipment and the skills necessary to make every replicated disc just as good as the original. The process we use for DVD Replication is essentially the same as with CD Replication, with a few minor changes.

 

There are a number of various formats that can be used for the original master disc. For example, a DVD-5 has the lowest capacity of 4.7 gigabytes, and can hold about 2 hours of video. Disc writers can write a single-layer of data on these discs, and only on one side.

 

The next step up is DVD-9, which holds 8.5 gigabytes of data, and has one recordable side, but has capability for a dual-layer data writing. These discs are good for up to 4 hours of video. If your video is any longer than 120 m, then you will want one of these discs for recording.

 

And, finally, the third popular format is DVD-10, which is like having two DVD-5’s glued together, because they have a single recordable layer on each side. Total capacity is 9.40 gigabytes, and it can hold up to a total of 4 hours of video. You would need to flip the disc over to get to the data stored on the opposite side, but they are surprisingly convenient for a variety of reasons.

 

Once you have your master DVD ready to be replicated, you can drop it off at the nearest FedEx location – and Abet Disc will even pay the shipping charges!

 

With no extra charge for full-color offset on-disc printing, Abet Disc can help you in all aspects of DVD Replication and packaging! Everything from Amaray cases, inner inserts, and DigiPaks, to Eco Paper Sleeves, Eco Sleeve / Jacket & Wallet, CarDisc / Flex & Mini Disc, Bulk Flex and Retail-Ready Flex DVDs.

 

Remember that we include a free barcode with all DVD Replication orders, have a 30-Day Price Matching Guarantee and a 100% Quality Assurance. Are you ready to get started? Give us a call today, and let us answer any questions that you may have!

 

CD Replication

CD Replication services are great for making 500 or more copies of one master CD. The difference between CD Duplication and CD Replication processes is that the former records data sequentially onto a disc, while the latter uses a stamping process that transfers the information all at once.

 

CD Replication, or Compact Disc Manufacturing, process used by Abet Disc ensures that every copy of your original master disc is replicated with the utmost precision and accuracy. First, a laser is used to etch a duplicate of your original CD master onto a glass plate. This plate is too fragile to be used for replication, so it is primarily used to make metal “stampers,” which can then be used to replicate your original CD.

 

The next step uses electroforming to plate the glass base with metal, which copies all the pits and lands of the original master disc onto the new, “Father stamper.” From there, the Father stamper becomes “the master copy,” so to speak, and is used to make hundreds of other CD replicas.

 

This is done by inserting the stamper into an automatic injection machine, which uses thermoplastic polymer substance to create a plastic-disc replica of the Father disc. It can make many such discs in a relatively short period of time, which is why CD Replication is typically used for quantities of 500 and more.

 

The plastic replica made in the injection machine is actually transparent, and cannot be read by a player – the laser beam goes right through it. Therefore, a very thin aluminum coat is applied to its surface, which is then covered with protective lacquer against scratches.

 

This highly intricate process requires accuracy and experience with the chemical components involved, so as to ensure that the transfer of data goes very smoothly. The coordination of all the steps in the process has to be quite precise too. Afterward, each finished CD is then put through a very high-quality full-color offset on-disc printing process. The best part is that, unlike some competitors, Abet Disc does not charge extra for the full-color printing!

 

At Abet Disc, we believe in providing our clients with the best quality product, because this ensures that their talents, whether it be music, software, games, or any other proprietary data, are well represented by every disc we replicate. Most of the time, CD Replication has superior quality advantages over CD Duplication, which is why you will find that Abet Disc is one of the only companies that offers CD Replication services starting at 100+ CDs!

 

Abet Disc is a well-established company and can fulfill all aspects of CD Replication and packaging. This includes Card Disc / Mini Disc CD Replication, DigiPak, Eco Wallet 4 & 6 panel CD, Jewel Case 2 – 8 panel CD, O Card / Slipcase, Paper Sleeve CD, Poly / Amaray / DVD case CD, Sleeve / Jacket CD, Spine Labels, and more.

 

Don’t forget that we also give you a free certified barcode with every CD Replication order, and even pay for your master disc shipping – something you won’t find with other companies!

 

With us, you can expect to find the highest quality in the industry, along with some of the best prices! Our goal is to consistently meet and exceed our clients’ expectations, and with over 20 years of experience in the industry, we stand behind our products with a 30-Day Price Matching Guarantee and 100% Quality Guarantee!

 

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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