Optical Disc Manufacturing Process
This process consists of 5 steps, pre-mastering, mastering, replication, printing and inspection.
Pre-Mastering/Mastering
We receive content and based on music, games, movie format, we proceed with the data conversion, error correction coding, and signal modulation.
For CD and DVD, the sounds or data signals are recorded as pits by a Sony laser beam recorder on a resist coated glass plate which is called a glass master.
From the glass master, a more durable metal master is created and through an electroplating process mothers and stampers are created in order to facilitate a mass production process.
For BD, the pits are recorded on an inorganic resist layer coating which is on top of the silicon substrate using Sony PTM system. Master stampers are created using the electroplating process.
Replication
The stamper is set onto the injection molding machine. The polycarbonate resin is injected to make transparent substrates with pits. The reflective layer is coated for signal reading. The cover layer, the interlayer and the protective layer of the disc are formed by using the spin coater and UV lamp.
< CD >
The pit surface of the disc substrate is coated with aluminum in order to reflect laser beams. UV curing resin is coated on it and dried to form a hard protective coating.
< DVD >
The transparent substrate is coated with a reflective layer, and a UV curing resin is dispensed to bond two discs for making a pairing disc.
< BD >
Silver is coated on the transparent 1.1 mm thickness substrate. After the cover layer is applied, the disc is cured with UV rays. A UV curing resin is coated on the disc to form a hard coat layer for the prevention of scratches and dirt.
Printing
Using high performance printing machines, which are capable of multicolor printing in high resolution, titles and designs are printed on the protective layer of the disc.
Inspection
Inspect disc signal and disc quality to make sure that disc fulfills standard.
