DVD replication is the process of producing multiple, identical copies of a master DVD, using a glass master that is created from the client’s original master disc, which ensures each copy is as perfect as the original. The data is transferred during the manufacturing process.
The glass master is a glass plate, cleaned with special detergents and coated in a special chemical that is burned off using laser technology, hardening the glass. However, it is still delicate at this stage, so a process known as electroforming is undertaken in which the master is rotated in a plating tank for approximately one hour to create a uniform, very thin nickel layer. A negative is created from the master, known as a “stamper” which then presses the data from the master onto every subsequent disc. This data transfer is achieved through a specialised procedure involving precision injection moulding of clear discs and subsequent additional treatment to create the finished DVDs.
Having checked the original disc for any data corruption and having made a perfect glass master, great care has to be exercised at each stage in production as any contamination or flaws will impair the quality of the copies. In addition to stringent quality control measures, the production takes place in a “clean room” to eliminate any possible airborne contaminant material from affecting the quality of the master and subsequent copies. The production process itself requires specialist equipment and technicians, therefore the set up costs to the customer for manufacturing DVDs in this way are higher than they would be for “duplication” but as this process is used for large volumes of copies, it actually works out as very cost-effective.
The amount of data that can be stored on a DVD created in this way is also considerable, and far more than a CD could hold. Interactive menus, chapter breaks, subtitles and other additional features can also be facilitated for each disc; a process known as “authoring.” Depending on the amount of data, one or both sides of a disc can be used, as well as the multi-layering of a disc, where one layer of data can be placed on top of another without impairing the functionality of the finished disc.
A coding system is used to distinguish which type of DVD is produced, the standard codes being DVD 5 and DVD 9. A DVD 5 disc contains a single layer of data on one side only. A DVD 9 disc contains two layers of data on the same side (multi-layered). Discs can also be produced with data on both sides, and the choice of format will be largely governed by the amount of data required on each and the level of functionality required.
The DVD replication process provides for perfect copies of data onto Blu-Ray DVDs as well, which can hold much larger amounts of data, and provide higher specification performance and functionality than standard DVDs. There are many companies with the facilities required for replicating DVDs, and most also provide associated services.
About the author:
Martin Jonson is director of the UK’s leading DVD/Blu-ray/CD duplication company providing exceptional quality at the lowest UK prices. He offers next day delivery anywhere in the UK and will complete your job quickly with the greatest care. You can connect with him on Google+.