Duplication and pressing are two different manufacturing processes. One is suitable for short runs and can be done within 24 hours; the other is suitable for quantities in excess of 200 pieces and allows us to offer an extremely low unit price.
Pressing consists of making a glass master from an original media (or master) which in turn allows a stamper to be produced. This is an industrial mould made of nickel used in high-speed plastic injection.
Liquid polycarbonate is then injected at high pressure into an industrial press fitted with the stamper to obtain a transparent disc (with a thickness of 1.2 mm) which already includes the master's binary coding.
The injection cycle takes less than three seconds.
All that remains to be done is to cover the CD with a coating of aluminum which produces a mirror effect (to reflect back the laser beam), over which is applied a film of varnish (to protect against oxidation) and to print your visual (label) by screen printing or offset.
In the case of a DVD, two 0.6 mm discs are produced. These are then glued together using a polymer resin.
In the case of a DVD5 (4.7GB.), only one of the discs contains the binary coding. The other is used only as a spacer to obtain the desired 1.2 mm thickness.
This pressing (or replication) technique is expensive for short runs because the creation of the glass master and stamper is complex. The injection phase, on the other hand, is relatively cheap, which makes the process perfect for runs above 200 units.
Duplication or burning is advisable for short runs and allows delivery of the finished product in under 24 hours, depending on the particular case. The original source is copied on to a robot which burns blank CD-Rs or DVD-Rs using a red or orange frequency laser. The CD-R or DVD-R media therefore already exist. They are then printed, using an ink-jet printer or thermal re-transfer.
Attention: DVD-Rs are not compatible with all home players.