In-House Manufacturing
Mastering Service
Stamper
Data mould for creating
CD / DVD / Blu-ray discs
Optical Disc Manufacturing is the process of producing commercial optical discs. The process differs from optical disc burning. Burners write data sequentially, while in our factory, pressing plant 'writes' the entire disk in one physical stamping operation. The stampers are the moulds used to stamp the data on to the discs.
Mastering
Premastering
All disks are pressed from a digital data source with the most common sources being low error-rate recordable disks or files from an attached computer hard drive containing the finished data (e. g., music or computer data). In premastering sessions the creative processing of the mixed audio recordings is done by which the finished data is converted into a format playable in respective players.
Glass Mastering
During glass mastering, glass is used as a substrate to hold the master image of the disk to be replicated while it is created and processed. Glass substrates are round plates of glass that are noticeably larger than a CD/DVD/Blu-ray disk. Once the glass substrate is cleaned using detergents and ultrasonic baths, the glass is placed in a spin coater. The spin coater rinses the glass blank with a solvent and then applies either photoresist or dye-polymer depending on the mastering process. Rotation spreads photoresist or dye-polymer coating evenly across the surface of the glass. The substrate is removed and baked to dry the coating and the glass substrate is ready for mastering. The data is then written on the glass substrate using laser beam recording technique. The Glass Master is thus created.
Post-Mastering
In post-mastering process, the glass master is baked to harden the developed surface material to prepare for metallization which is the process of getting nickel vapour deposited onto the glass master.
Electroforming
In post-mastering process, the glass master is baked to harden the developed surface material to prepare for metallization which is the process of getting nickel vapour deposited onto the glass master. To make stampers, electroforming is done which is an opposite process of normal electroplating. Mirror image of glass master thus created using nickel through this process. Stampers are used as moulds for stamping during the injection moulding of optical discs. Bulk-replication wears out the stamper which needs to be replaced at regular intervals. Painstaking effort is made to ensure consistency of each stamper. Maintaining the uniformity of the stamper is essential so exactly the same discs can be produced throughout the repeated replication process.