From Start to Finish

CD-ROM replication is a very different process from CD-R duplication or copying. Usually the replication process is the choice when large volume production is required.

At a minimum CD-ROM replication involves the following steps.

1. Glass mastering & stamper production.
   A glass master is produced from a customer supplied CD-R by an advanced chemical etching process. Once a reliable glass master is obtained, metal stampers are produced for use in the injection molding machines that will replicate the discs.
   
   
   
2. Replication using high-speed injection molding equipment.
   Stampers are loaded into high-speed injection molding equipment. Liquid polycarbonate material, under high pressure, is injected into the mold cavity. The metal stamper produces a plastic disc, 120mm in diameter with information laid out on predefined data tracks. Stampers produce a disc in approximately 5-6 seconds.
   
   
   
3. Application of reflective aluminum via spin coating.
   A thin coating of aluminum is applied to the top surface of the disc via a controlled spin coating process. Aluminum provides the necessary reflective surface that allows the laser in standard readers to pick up and identify data stored on disc. After the aluminum has been applied, an additional layer of lacquer is laid down to protect the top surface of the disc.
   
   
   
4. Test and verification of manufactured CD-ROM.
   Replicated discs are checked for proper signal strength. Block error data rates are determined. Should a disc be found to have a block error rate out of allowable limits, it is rejected. Other tests, including a jitter analysis, are performed to ensure quality of the replicated product.
   
   
   
5. Custom labeling via traditional silk-screen or digital printing.
   Verified discs are automatically placed on spindles (usually 150 pieces each) and delivered for custom labeling. Special data is encoded on the discs to identify them from other products produced at the plant. Discs can be labeled using advance silk-screening or digital printing presses in up to 6 colors.
   
   
   
6. Packaging and assembly of discs.
   Once properly labeled, discs are ready for final packaging and assembly. Typically, discs can be inserted into plastic jewel cases, clamshells, mailers, paper or tyvec sleeves, or placed in bulk on 150 piece spindles and then shrink-wrapped. Once assembled, discs are packaged in appropriate packaging containers and delivered to shipping.