DVD To DVD Copies: Duplication And Replication Processes Expounded
March 18th, 2011 | Author: admin
While pretty much everyone knows what a DVD (Digital Versatile Disc) is, far fewer have an idea of the differences between disc duplication and disc replication. If you need to make a lot of DVD to DVD copies, and are not sure which option to go for, the information below should help.
Disc Duplication Is A Copying Process: Information from a master is written to ready-made blank discs to make duplicates. This process is often referred to as ‘burning’ because a laser is used to heat and literally burn marks into the disc’s chemical dye layer. These marks are read as data.
Using high quality blanks is very important, since the chemical dye is actually inside the disc itself, and any manufacturing flaws in the dye layer can result in uneven burns and therefore corrupted data. This is similar to the process that is used to create one-for-one copies on a personal computer’s DVD drive.
Large duplication towers are units that contain many disc trays, meaning they burn several discs at a time (potentially hundreds, depending on how many units are linked together). Some facilities have robotic duplicators, which sport arms that load and unload the discs, cutting the need for a human operator.
Disc Replication Is A Manufacturing Process: Replication takes several steps and includes the physical manufacture of each disc. First, the client-provided master data is meticulously analyzed for any corruption. Once data integrity is assured, a blank glass plate is created. A laser writes the master data on the plate’s surface by etching pits into the glass – pits for ’1′, rises for ’0′. This is the glass master.
Tough metal stampers are created from the glass master (which is used as a mold). These stampers are connected to injection molding machines. Melted plastic (a durable polycarbonate) is injected into the mold at high-pressure. The stamper presses into the polycarbonate, imprints the data and thus creates a transparent plastic replicate. A micro-thin reflective layer of metal is applied. A coat of lacquer (UV light flash cured) is applied to provide added protection and a printable surface for labels.
Pros and Cons: Duplication offers short turn-times (2 to 3 days), but is suitable mainly for low-volume runs (100 to 5,000 DVD to DVD copies). Duplicates are suitable for hi-res digital- and thermal press printing. Most duplication facilities are fairly small and limited to hand-packaging the discs. Replication has a longer turn-time (7 to 10 days, longer for runs higher than 100,000), but is suitable for high-volume runs, and the cost-per-disc is lower. Replicates are suitable for screen and offset printing. Most replicate facilities offer automated packaging.
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