How does a DVD get replicated?

DVD replication is the process by which contents of a source master are transferred to other DVD discs. After the source master has been submitted to the DVD replication plant it will be checked for any discrepancies such as unreadable sectors or corrupt portions. This is a very important step before the DVD gets replicated because such corruptions could leak onto all the copies leading to a waste of money and time.

DVD replication includes the following steps:

Mastering
DVD mastering is a digital optimisation process which readies the DVD project for replication. A substrate treated with a photosensitive layer is prepared. A laser beam recorder is used to transfer the data or music. A developing solution enables the laser exposed zones to be removed.

Electroplating
This involves mounting the glass master and immersing it into a solution of nickel sulfamate. A process of electrolysis takes place between the two electrodes; the anode and the cathode. This leads to the creation of a nickel layer, separated from the glass master for obtaining the stamper.

Moulding
The stamper is placed in a special mould under very high pressure and then held together. Molten polycarbonate is injected into the mould and after a few seconds of cooling down a new clear disc is then ejected.

After this, the DVD is sent for pre-press and screen printing, which prints the DVD with the image or designs that you have selected.

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