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BlurayProductionprocess

Blurayproductionprocess

1.Premastering
Thisisaprocesswherecustomersdigitaldataisspecificallypreparedandtransferredintotheappropriate
formatforfurtherstamperproduction.Incasetheparametersofthematerialprovidedbyacustomerdonot
complywithstamperanddiscreplicationrequirements,technicaldatacanbecorrectedduringthepremastering
stage.

2.Testing
Inparticular,wemakesurethatthematerialprovidedbycustomermeetsallrequiredstandardsandisfairly
readablebyaplayer.Thematerialisrecordedintotheinformationstoragedeviceandtestedinaspecialtesting
deviceforsuitabilityforfurtherstamperproduction.

3.Mastering
Atthisstage,auniquemould,socalledstamper,isproduced.Thestampersareusedtomakeadiscingotfor
furtherreplication.
Toproduceastampertheglassmouldwithapieceofphotoresist(lightsensitivelayer)isused,inwhichalaser
beam"records"theinformationthatisgoingtobeinreplicateddiscs.
Recordedglassmouldisplacedinaspecialgalvanicfacilitywherethenickellayerisgrownwithahelpof
electrolysis.Afterwards,alayerofnickelisseparatedfromtheglassmould.Thisproducesastampera
negativediscimage,whichisusedtoreplicatethediscs.

4.Moulding
Whenthestamperismade,thediscreplicationisstarted.
Thoroughlycleanedstamperisplacedintoamould,whichisclosedandthecastingprocessbegins.Usinga
syringeinjectswithacontrolled,upto~360degreesheatedliquidpolycarbonate,aCD/DVDmasterispoured
out.Italreadycontainsdigitalinformation,butitstillcannotbescannedbyalaserbeam,becausethediscis
completelytransparent.
WhenreplicatingBDs,theonediscmouldisprepared(thickness1,1mm).

5.Metallization
Oneofthecleardiscsideswiththeimprintedinformationiscoveredwithsilverlayerof35nmthickness.This
actsasamirrorreflectingalaserbeamtoreadtheinformation.

6.BaseResin(onlyforBD50)
Thefirstlayerofmetallizationisvarnishedandcoveredwithspecialresin,whichwillbebetweentworecorded
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BlurayProductionprocess

layers.

7.WetEmbossing(onlyforBD50)
Atthisstageawetresinlayerisformed.Afterpressingastamperintothislayer,theinformationstaysinthe
disc.BeforepullingthestamperfromthesurfaceofthediscitisdriedusingUVrays.

8.Layer1Metallization(onlyforBD50)
Thesecondrecordedlayerismadeusingsemireflectivematerial.Itiscoveredwithsilveralloywithathickness
ofapprox.30nm.

9.CoverLayer
Atthisstageacoverlayeriscoveredwithlacquerwhichisneededforlaserbeamtoreadtheinformationinside
thedisccorrectly.

10.ProtectionCoating
Whenthementionedproductionstepsarefinished,thedisciscoatedwithadditionalprotectivelayers:hard
coatingandmoisturebarrier.Suchacoatingprotectsthediscformnegativeenvironmentconditions,suchas
smallscratchesandmoisture.

11.FinalInspection
Thesystemmeasuresthethicknessanduniformityofthelayersuniquelayerthicknessandapprovesthedisc
quality.

12.Printing
Screenprintingoroffsetprintingmethodcanbeusedtocoverthediscsaccordingtothecustomersprovided
graphicdesign.Thelatesttechnologiesallowustoprintthediscsaccordingtothehighestqualitystandards.

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