The Process - CDs

There are two ways to create a copied CD.

The first is by 'burning' the data onto a pre formed blank disc (a CD-R) - as you would with a PC CD or DVD burner. A laser etches the pits of information in to a dye layer contained within the blank disc.
This is called CD duplication and is sometimes referred to as CD copying. The product itself is a CD-r.

The second is by 'pressing' the discs with a nickel 'stamper' produced from a 'Glass Master' in a manufacturing plant. (Similar to, but a much more refined process than the method used to create vinyl records). This process is often referred to as CD replication or CD pressing. The product itself is a CD-ROM.

CD Duplication
Duplicated CDrs are discs produced by burning information on to recordable discs. They may then be printed using our full colour thermal printers. These printers produce a high quality glossy finish which is extremely durable. The duplication process is usually suited to CD volumes of 500 or less.

All our duplicated discs are subjected to 100% bit for bit verification with your original master to ensure that they are an exact copy. At this stage in the process, any discs that fail this test are automatically rejected.

This process is more labour intensive and so duplicated discs are more expensive than replicated discs. So if you require more than 500 units and time permits, then it is more cost effective to press CDs than to duplicate them.

CD Replication / CD Pressing
CD replication or pressing refers to the process of manufacturing bulk CD ROMs using a stamping and moulding process. (This is the process normally used for music CDs that you buy in the High Street.) The process is usually suited to CD volumes of 500 or more.

The CD replication process requires that a “Glass Master” and “stamper” are produced from your supplied CD master. Stamper making is a critical part of the process. Once the nickel stamper has been tested and inserted in to the moulding machine the manufacturing process is very fast; approximately 3-4 seconds per CD. A very fine 'silver' layer of aluminium is “sputtered” on to the plastic disc, another layer of polycarbonate is sprayed over the metalized layer and then these discs are optically inspected for defects prior to having the artwork information screen printed or offset printed on to them.

Once the discs have been produced they will require some kind of image to be printed on them. This could be text only, text and logos or a full colour image across the surface of the disc. With replicated CDs the artwork on the disc is usually printed in one or two ways, screen printed or offset printed. The quality of each type of print is very high and is usually around 300dpi and produced from a four colour or CMYK artwork file. Specific PMS (pantone) colours can also be requested up to a total of 5 colours. Artwork files may be emailed to us and we have a convenient FTP facility if you wish to upload an ISO image of your CD master.