CD Replication

Commercial CD replication is a highly controlled manufacturing process designed to deliver durable, high‑fidelity discs with exceptional data integrity. Unlike CD‑R duplication, replication produces mass‑manufactured discs using a precisely engineered master template, ensuring consistent quality across large production runs.

 

Our Replication Process

 

1. Glass Mastering Production begins with the creation of a glass master, the definitive template for all discs. Audio or data is prepared and encoded into a DDP image, then etched onto a photoresist‑coated glass disc using a laser beam recorder. This clean‑room process ensures absolute precision.

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2. Electroforming The glass master is metallized with silver and electroplated with nickel to create a negative metal stamper. Multiple stampers can be produced to support high‑volume manufacturing.

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3. Injection Moulding Polycarbonate granules are heated and injected into moulds containing the stamper. The stamper imprints the pits and lands that form the digital data pattern, producing a flawless disc substrate.

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4. Metallization & Protective Coating A micro‑thin aluminium layer is vacuum‑deposited onto the disc to create the reflective surface required for laser reading. A UV‑cured acrylic coating is then applied to protect the disc from scratches and oxidation.

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5. Printing & Quality Control Discs are printed using high‑quality screen or offset printing. Each unit undergoes rigorous optical and electrical testing to ensure perfect readability and mechanical integrity before packaging.