CD Production process

CD (Compact Disc) is an optical storage medium for storage of digital data. CD format was firstly developed for sound recording and only later became popular for storage of a variety of other files. These disks entered a broad market in 1982 and now are used both for storage of data and for promotional purposes.
Many people, who have not confronted with optical storage media production details, mistakenly believe the CD to be only a standard 12 cm diameter disk for storage of music or files. In reality, we have a much wider availability of CDs. Depending on the disc content and structure, there is a variety of CD format, and CD types specify the disc image and shape.

12 cm CD

12 cm diameter CD disc is a standard CD disc.

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12 cm CD

12 cm CD is a standard CD disc that are used mostly for music records and other data storage.

8 cm CD

8 cm CD can be very attractive promotional tool.

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8 cm CD

8 cm CD can be very attractive promotional tool. Such a disc can contain up to 21 min. 30 sek. of audio record or up to 192 MB of information. We also can offer special plastic cases and cardboard wallets for 8 cm CDs.

Business card CD

CD business card is a visit card with recorded info.

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Business card CD

CD business card is a visit card with recorded information about the company (presentation, video). It is the innovative solution replacing standard paper visit cards and flyers. CD business cards are reliable and long-lasting, because they are water and heat resistant. Usually CD business cards are packed into special plastic wallets.

  Capacity[MB] Size[mm] Measurements[mm]
20 54,0 x 84,0 56,0 x 86,0
25 55,0 x 84,0 57,0 x 86,0
30 56,0 x 84,0 58,0 x 86,0
40 57,5 x 84,0 59,5 x 86,0
50 59,0 x 84,0 61,0 x 86,0

Golden CD

CDs are covered with a golden-color metal layer.

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Golden CD

CDs are covered with a golden-color metal layer instead of standard metallization. In this way we get a solid looking exclusive disc. We can replicate Golden CDs with partial metallization or graphic mastering.

Graphic CD

We can add graphic mastering to all kinds of CDs.

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Graphic CD

We can add graphic mastering to all kinds of CDs. This technology allows us to print your required text or logo on pre-recorded disc side. SCAPE system allows to painting the pictures and writing a text on the stamper surface. Later this record is printed on CD.

Transparent CD

Transparent CD is a CD with a partial metallisation.

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Transparent CD

Transparent CD is a CD with a partial metallisation. During the production process only a part of the disc is covered with aluminium layer (silver or golden colour). This option creates very unusual look to the disc. Such CD can contain up to 250 MG of information.

Shaped CD

Shaped CDs are cut according to your requirements.

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Shaped CD

Shaped CDs are cut according to your requirements. We can offer a range of different forms: square, hexagonal, ellipse, etc. First of all a standard CD is produced and afterwards it is cut according to requested form.

Aromatic CD

We can you offer CDs with various odours.

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Aromatic CD

We can offer CDs with various odours. Our technologies allows to produce the discs with various long-term odours by adding it to the paints. We can flavour just a part of CD surface, which smells more after rubbing. Such CDs are very attractive promotional tools.

CD production process

1. Premastering

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.

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2. Testing

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.

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3. Mastering

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 mold. This produces a stamper – a negative disc image, which is used to replicate the discs.

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4. Moulding

When the stamper 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 CDs, the one disc mould is prepared (thickness - 1,2 mm), while replicating DVDs - two disc moulds are prepared and glued afterwards (thickness - 0.6 mm of each).

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5. Metallisation

One of the clear disc side with the imprinted information is covered with aluminium. This acts as a mirror reflecting a laser beam to read the information.
When replicating DVDs, the number and composition of metallisation layers depend on DVD format and capacity (DVD-5, DVD-9 or DVD-10).

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6. Varnishing

Metal layer formed on the disk after metallisation process is very thin and in case of any infringements the information will not be readable. That is why the discs are covered with a special varnish dried with UV rays. When replicating DVDs, the moulds are “glued” together using special UV glues without varnishing, because the information stays in the inner side and does not have to be protected.

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7. Printing

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.

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