DVD Production process

DVDs (Digital Versatile Disc) has the same physical parameters as CD; however each DVD consists of two “bonded” layers of 0.6 mm and stores more data. BOD Group plants manufacture DVD-5, DVD-9 and DVD-10, which differ by capacity of the stored data.
DVD format was developed and upgraded in 1995 by such companies as Philips, Sony, Toshiba, and Panasonic. Although DVD has already a more advanced version, Blu-Ray format, it is still widely used. Depending on the disc content, structure, and capacity, there is a variety of DVD format, and DVD types specify the disc image and shape.

12 cm DVD

12 cm DVD is a standard size for DVD disc.

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12 cm DVD

12 cm DVDs are standard DVD discs that are used for video or music records as well as for other data storage.

Golden DVD

DVDs are covered with a golden-color metal layer.

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Golden DVD

DVDs 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 DVDs with partial metallization or graphic mastering.

Black DVD

DVDs are covered with a black-color metal layer.

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Black DVD

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

Graphic DVD

We can add graphic mastering to all kinds of DVDs.

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Graphic DVD

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

DVD 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 mould. 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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