In CD replication many stages and steps are included. The first stage in producing CD and DVD discs is injection Moulding. Stamper creates the plastic discs or substrates containing the pits.
- In a high pressure moulding machine (press) first ‘baked’ to remove any moisture and is injection moulded.
- Optical grade polycarbonate is using the stamper mounted in the mould fixed to the press.
- In two parts this mould provides a hollow space to make it sure that molded disc is produced in correct dimension.
- This check is done at every time. The Half of mould contains the stamper (to form the pits). To ensure a smooth surface themirror block is here. The hydraulic press applies a force to the two halves of the closed mould.
- Then inject the Molten polycarbonate into the hollow space and held in place by the applied pressure while the disc cools and solidifies. At the time of cooling the centre hole is punched. The press opens after cooling. The pressed disc is transferred by robot arms. To a conveyor it allows the disc to cool before the next stage. Then the centre hole (formed by the injected polycarbonate) is discarded.
Successful moulding of CDs which meet the CD specification requires stable processes with the machines setup correctly. Moulding limitations can affect the resultant CD include stamper geometry, mould temperature, polycarbonate temperature, and compression force and cycle time. Cycle times for injection moulding of CDs have decreased. It is around 3 seconds for the latest presses and moulds.
CD Moulding and DVD Moulding
- DVD moulding is similar to CD moulding but little differences are here
- DVD needed two pressings for each final DVD disc
- Each half disc (substrate) is 0.6mm thick
- For thinner disc different moulding parameters are required
- Shorter injection time and higher mould temperature are part of it
- The mould is kept slightly apart until most of the polycarbonate has been injected
Easy replication is doing the best CD replication with CD Moulding that effect positively on production process. It supports to get excellent results. That is the reason experts prefer CD replication from here. See Details
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