CD and DVD Replication - How It Works.
CD and DVD replication is a process that works by creating discs from scratch.
Not to be confused with duplication (the act of burning information onto
ready-made, commercially-available blank CD-Rs and DVD-Rs), replication relies
on the use of molds to produce actual discs that already contain digital data.
It is the preferred and recommended mode of mass production for quantities in
excess of 500 units.
Replication begins with a painstaking process called glass mastering. In this
step, a laser is used to copy data onto a light-reactive glass plate. The plates
photosensitive glaze reacts to the heat of the laser, thus etching several
gigabytes worth of digital information for permanent storage.
The data encoded on the glass master comes in binary form, a series of 1s and
0s. While these 1s and 0s may seem like gobbledygook to the average human, it is
the language that CD and DVD players understand. Once scored onto the plate via
laser, binary information appears as very tiny depressions of varying depths,
similar to the grooves on a vinyl record.
Since a glass master cannot be altered once it is completed, great care must be
taken when preparing one. As a quality control measure, it has to be made in a
clean room environment. Any defects or impurities on the glass master will
definitely compromise the integrity and playability of the final CDs or DVDs.
A glass master is considered too delicate to be used for heavy-duty and
large-scale disc production. Instead, it is used to create several sturdier,
more durable metal molds called stampers. In a process known as stamping
or pressing, each stamper is injected with a transparent plastic substance
called polycarbonate. The excess plastic is then removed, leaving an exact
impression of the mold.
To make the polycarbonate disc suitable for playing, it is then finished with a
coat of reflective material. Once the replication process is completed, the disc
is finally ready for labeling and packaging.
Replication is considered to be superior to disc duplication. As such, it is
regarded as the industry standard. This is because it offers greater consistency
in production quality and disc playability than the burning process. In a sense,
burning may be likened to photocopying while copying may be likened to cloning.
Replicated discs are exact and faithful reproductions of their glass masters;
duplicated discs, on the other hand, may differ from their source depending on
the quality of the blank media used.
However, due to the complicated and tedious nature of CD and DVD replication,
its turn-around or completion time is considerably longer than that of
duplication. Depending on the number of copies, discs may be duplicated within a
matter of minutes. In contrast, a batch of discs can take two to four weeks to
replicate.
Replication is also best left to the experts. Owing to the need for clean rooms
and special equipment, the startup expense and preparation can be costlier as
well as resource-intensive. But in the long run, replication yields a lower
per-unit-cost than disc burning.
Are you looking for tips to make DVD burning a stress-free experience? Below are
a few practical and sensible tips that will help you circumvent common DVD
burning and playback problems.
Disc copiers will tell you, DVD burning is not rocket science. There is no
secret formula to success. Nor is there an IQ requirement to get the job done.
There is, however, a need for a bit of common sense. Read on and discover things
you probably already know but do not necessarily practice.
1. Always use reliable media. The quality of the blank DVD-R used often gets the
blame for the bulk of burning errors. And while it isnt always the only culprit,
neither is it merely a scapegoat. The kind of blank media you use can and does
affect the integrity of your finished product.
Burning starts with selecting the right blank media. Right does not always mean
expensive though. Many reliable brands are reasonably priced. Generally,
however, very cheap discs fall short of being right. So think twice before
scrimping on DVD-Rs. In the long run, the little that you do save may cost you
more in the form of defective copies.
2. Examine each and every disc. Occasionally, faulty discs can slip through the
quality control inspection of even the most reputable manufacturers. Before
burning, inspect the recordable underside of each DVD-R for cracks, scratches,
spots and blotches. Physical defects, especially those on the discs
photosensitive layer, will cause recording flaws and playback distortions.
3. Keep things clean. Burning errors can arise from the use of unclean hardware
or media. Dust the outside of your DVD burner regularly to prevent contaminants
from reaching the laser eye. Also handle and store discs with care. Keep them
free of dust, grime or grease that may result in imperfect and unplayable
copies.
4. Choose your software and hardware wisely. Look for user-friendly software
that you can effortlessly navigate through. If your software has a complicated
interface, you can easily make mistakes that can undermine the burning process.
Also make sure that both your DVD burner and software have good customer tech
support. When things go wrong, it always helps to consult the experts.
5. Keep your software updated. Burning errors are sometimes due to software
bugs. Once anomalies are detected, software designers devise patches to remedy
them. If you register your burning application and regularly install updates,
you could save yourself a lot of needless trouble.
6. Check for compatibility. The format of the disc can dictate its playability.
By default, the Universal Disc Format (UDF) specifications of most burning
programs are automatically set at UDF 1.5. However, UDF 1.5 cannot be read by
all drives and players. By switching to UDF 1.02 you can make your discs
readable across the board. Do not panic, it is not as complicated as it sounds.
You can easily assign UDF values from a list or dropdown menu.
7. Do not multitask. For quicker and more efficient disc burning, turn off all
other programs, including antivirus software, games and screensavers. The
burning process is resource intensive. If you have other applications running in
the background, the procedure may take longer than necessary. By overtaxing your
system, you also leave yourself open to avoidable burning errors.
8. Do not rush things. If you have time on your hands, burn at slower speeds.
Doing so will reduce the risk of errors. If you are willing to endure the wait,
burning at slower speeds can yield more stable and higher quality DVDs.
9. Label with care. How you tag your DVDs can affect their performance. If you
do not want to invest in a new hardware that can print directly onto blank
discs, you can choose either of the following options.
a. Simply write on your disc. But be sure to write lightly
using a felt-tipped pen. Sharp writing instruments may scrape through the
topmost stratum of the disc and damage the fragile recordable layer underneath
it.
b. Use adhesive labels. Opt for the full, donut-style
stickers that cover the entire disc. Avoid tiny stickers (such as mailing
labels) that can affect the balance and performance of your DVD as it spins in
your player. Small labels can also easily come loose and damage your player
during playback.
DVD burning problems are often the result of a compendium of mistakes, many
of which can be avoided using good old common sense.
If you do not overlook the obvious, burning can be a no-brainer, really. |
