DVD Replication
At easyreplication, expertise knowledge and state-of-the-art technology come together to transform your vision into reality. easyreplication is well equipped to handle every master format you need to replicate DVDs for a feature film, documentary, how-to video, or make copies of your corporation’s presentations and press releases..
The process follows a precise movement of well-implemented knowledge and the latest advanced technology and control systems. Therefore, for DVD replication orders over 500 units, your glass master and subsequent DVD copies are guaranteed to perfectly match the original master using by manufacturing DVDs on a replication line.
Executed with complete precision, the DVD replication process is as follows: The glass master is carefully manufactured in a sterile “clean room” environment (DVD-9 dual-layer discs and DVD-10 dual-sided discs require two glass masters) and the subsequent “stampers” are produced under the highest quality control systems. The facilities contain state-of-the-art specialized equipment that carefully monitors audio and video levels. We finalize your product by applying your customized artwork and labels.
In addition to our rigorous quality control systems, we guarantee your order will be completed to your individual standards, requirements and expectations. Every order is assessed for efficient production and supreme quality to meet only the highest standards and with the fastest turnaround in the industry.
easyreplication has a friendly and qualified customer service staff prepared to guide you through your project, from start to finish, ensuring your project is completed well within your scheduled deadline and budget.
Get your DVD replication Order Started today. Fill in our easyquotation form or call us 01236 62 66 22.
DVD Replication Technical Information
DVD replication services cater for those requiring upwards of 500 units.
What is the difference between a DVD and a CD?
Unlike a CD, a DVD consists of two sides made of plastic which are stuck together. These sides are also called layers. Data can be pressed at a far higher density on both layers than on a CD, giving the DVD a considerably greater storage capacity.
One medium, many possibilities
Depending on the amount of data, there are the following options:
- A single layer is pressed (DVD-5 up to 4.7 GB). As with a CD, the data is read from the bottom layer of the DVD by the laser of the DVD player and converted into image and sound signals.
- Two layers are pressed (DVD-9 up to 8.7 GB). With this kind of DVD, the top layer is also copied. The top layer can be read by the DVD player’s laser from underneath because the bottom layer has a semi-transparent mirror. The laser can read the data from the top layer through this mirror.
- Even more is possible (DVD-10 up to 9.4 GB). The capacity can be increased even further by copying the DVD on both sides. The procedure for playing a DVD-10 is similar to that of LPs – the DVD is turned over in order to play the second side.
Authoring
How does the film get from the reel to the disc?
To begin with, there is always a professional source master which is converted through a hardware encoder into MPEG-2 format. This is the required format for further processing.
Menus are created depending on the customer’s requirements, allowing the viewer to choose the content of the DVD directly (e.g. chapters), or make a selection from different types of content (such as special features).
During the authoring process, the audio and video content is linked to the menus which have previously been created. The actual programming takes place during the pre-mastering stage, as authoring is also referred as. This is done with specialist authoring software such as Sonic Creator.
At every single stage of this process, all operations are carefully checked and on completion go through another full inspection.
If the authoring has been undertaken by easyreplication and copy protection is to be included, the customer receives a copy in the form of a DVD-R once the inspection has taken place, so that he too can check if everything is as he expects. Once the customer has signed it off, the input medium (DLT – Digital Linear Tape) then continues through the mastering process in DVD replication.
Another option is for the customer to provide a DLT directly. In this event it proceeds directly to the mastering stage without any further signing off and checking.
Mastering in DVD Replication
Up to 2 glass masters are produced during the mastering process in dvd replication. A powerful laser beam transmits the data from pre-mastering on to a photo-resistant layer, creating what are known as “pits”. After the laser process, the photo-resist layer is chemically cleaned to allow it to then be metallized with nickel. This process is repeated for each layer until all of the data are complete.
A DVD has two fathers
The glass master is used as the template to produce the ‘father’, a nickel disc approximately 300µm thick. The father can now be used as a stamper, but only for small runs. Depending on which type of DVD it is, up to two fathers are required for the production of each DVD.
For large runs, you need a mother
The ‘mother’ is then produced from the father. Practically any number of stampers can be made from the mother. We call this process the ‘family development’.
Now the pressing and sticking can begin
For the pressing process, both stampers are placed in the mould of the injection moulding machine. The pit structure (containing the information) of the mothers are filled with liquid polycarbonate. Once they have cooled off, one half is coated with aluminium or silicon (the semi-transparent mirror for DVD-9). Both discs are stuck together with a UV curing adhesive. The DVD is now complete and ready to play.
DVD replication finishing
The DVDs have still to be printed of course. Using silkscreen or offset processes we print text, images or graphics onto the DVD – creativity knows virtually no bounds. We will be glad to show you samples of particular printing techniques. All the lacquers and colours guarantee a high level of durability
email sales@easyreplication.co.uk , fill in our `easyquotation` website form or to speak direct to one of our account managers please call 01236 62 66 22
