DVD 5

DVD5 is a single sided DVD that stores up to 4.7 GB of information.

DVD5 discs are made up from 2 disc layers which are bonded together. An approved quality assured stamper containing the user data information and a separate dummy stamper to produce a blank disc for making up the finished 1.2mm optical disc.

The Process

	Each stamper is mounted individually into it’s own injection moulding machine and conditioned polycarbonate granules are fed into the hopper of the injection screw

	The granules are heated to 345 degrees Celsius to produce a molten liquid which is injected into the mould cavity and forms around the protruding pit structure on the stamper with the data. The same process happens simultaneously in the moulding machine with the blank stamper.


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

	The moulded user data is now placed in a high vacuum chamber where a thin coat of aluminium is laid down 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 unreadable

	A layer of UV lacquer is applied to the metallised side of the data Disc and the 0.6mm dummy disc is placed on top

	This sandwich of discs, metal and lacquer is passed under a UV lamp to cure the lacquer and produces a finished 1.2mm bonded disc.

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

	The approved finished discs (stacked on a spindle) are ready for electrical and mechanical off-line testing in our Quality Control Department.

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

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DVD 5