DVD 10

DVD10 is a double sided layer DVD which can fit up to 9.4 GB of information.

Two approved quality assured DVD5 stampers containing the user data information, one for each layer is used for making up the finished optical disc.

The Process
	Both stampers are mounted in there respective moulds of the twin moulding system and conditioned polycarbonate granules are fed into the hopper of the injection screws

	The granules melt down to produce a moulting liquid plastic which is injected into the mould cavity and formed around the protruding pit structure on the stamper

	Cooling channels open the mould solidifying the moulding plastic into a 0.6mm solid polycarbonate discs, containing an exact reverse replica of the stampers pit structure

	The data discs are placed in two separate high vacuum chambers where a thin coat of metal is applied over the pit surfaces. This is called ‘Metalising’

	Metalising forms the reflective surface of the optical disc. (without this metal layer the laser light in the player will pass through the disc making it illegible)

	Both sides (one and two) are metallised with aluminium

	A layer of UV lacquer is applied between both discs forming a sandwich of discs, metal and lacquer is passed under a UV lamp to fix the lacquer and produces a finished 1.2mm bonded disc.

	The completed disc undergoes a physical inspection by camera to ensure the cosmetic criteria is within specification

	The approved finished discs are then stacked on a spindle ready for electrical and mechanical off-line testing in our quality control procedures

	Once approved the quality assured discs are now ready for printing and packing

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DVD 10