Blu-ray also known as Blu-ray Disc (BD) is an optical disc format developed by the Blu-ray Disc Association (BDA), which consists of the leading electronics, computing, and media corporations such as Apple, Dell, Hitachi, HP, JVC, LG, Mitsubishi, Panasonic, Pioneer, Philips, Samsung, Sharp, Sony, TDK, and Thomson.
Blu-ray format was designed to be able to restore high-definition video and to store large amounts of data, while 3D options provide unique effects. The diameter of a Blu-ray disc is the same as a CD or DVD but is capable to store far more data. Depending on the disc content and structure, there is a variety of Blu-ray formats, and Blu-ray disc types specify the disc capacity.
Blu-ray replication is the future in optical media. Right now, the technology can help store BD-25 (25GB) of data on single-layer blank discs, or BD-50 (50GB) twice that amount on dual layer discs. Soon, however, the layers could increase four-fold in the future raising the amount of data that can be encoded into the disc to 200GB.
easyreplication is the foremost service provider for your blu-ray replication needs. Whether you only need 500 discs to be copied or over 100,000 Blu-ray discs that are commercially ready for release, we are your one-stop digital media company.
Why you need Blu-ray replication:
- The format is in HD video
- Full interactivity
- Internet or network capability
- 7.1 channels of audio
- Scratch or dust-free
We can also encrypt the Blu-ray disc with protection to make sure that your data stays secure and will not be copied.
If you are a filmmaker Blu-ray discs will allow you to use many additional features built into the video, however. The interactive menu allows you to interact better with the users through navigation menus and animated buttons.
As you can see, the possibilities are endless with Blu-ray technology. And no matter what you have envisioned for the final product of your film, record album or product presentation, Easyreplication has the experience and expertise to handle all your conditions. We also have a wide range of designs for you to choose from in your packaging. We also offer our over 12 years-worth of experience in the industry to make sure you get your money’s worth when availing of our Blu-ray replication service.
The Blu-ray production process:
This is a process where customer’s digital data is specifically prepared and transferred into the appropriate format for further stamper production. In case the parameters of the material provided by a customer do not comply with stamper and disc replication requirements, technical data can be corrected during the premastering stage.
In particular, we make sure that the material provided by customer meets all required standards and is fairly readable by a player. The material is recorded into the information storage device and tested in a special testing device for suitability for further stamper production.
At this stage, a unique mould, so-called stamper, is produced. The stampers are used to make a disc ingot for further replication.
To produce a stamper the glass mould with a piece of photo-resist (light-sensitive layer) is used, in which a laser beam “records” the information that is going to be in replicated discs.
Recorded glass mould is placed in a special galvanic facility where the nickel layer is grown with a help of electrolysis. Afterwards, a layer of nickel is separated from the glass mould. This produces a stamper – a negative disc image, which is used to replicate the discs.
When the stamper for the Blu-ray disc is made, the disc replication is started. Thoroughly cleaned stamper is placed into a mould, which is closed and the casting process begins. Using a syringe injects with a controlled, up to ~ 360 degrees heated liquid polycarbonate, a CD/DVD master is poured out. It already contains digital information, but it still cannot be scanned by a laser beam, because the disc is completely transparent. When replicating Blu-ray (BDs), the one disc mould is prepared (thickness – 1,1 mm).
One of the clear disc sides with the imprinted information is covered with silver layer of 35 nm thickness. This acts as a mirror reflecting a laser beam to read the information.
6. Base Resin (only for BD50)
The first layer of metallization is varnished and covered with special resin, which will be between two recorded layers.
7. Wet-Embossing (only for BD50)
At this stage a wet resin layer is formed. After pressing a stamper into this layer, the information stays in the disc. Before pulling the stamper from the surface of the disc it is dried using UV rays.
8. Layer 1 Metallization (only for BD50)
The second recorded layer is made using semi-reflective material. It is covered with silver alloy with a thickness of approx. 30 nm.
9. Cover Layer
At this stage a cover layer is covered with lacquer which is needed for laser beam to read the information inside the disc correctly.
10. Protection Coating
When the mentioned production steps are finished, the Blu-ray disc is coated with additional protective layers: hard coating and moisture barrier. Such a coating protects the disc form negative environment conditions, such as small scratches and moisture.
11. Final Inspection
The system measures the thickness and uniformity of the layers unique layer thickness and approves the disc quality.
Screen printing or offset printing method can be used to cover the discs according to the customer’s provided graphic design. The latest technologies allow us to print the discs according to the highest quality standards.