CD Replication Manufacturing Service
CD replication is the term used when referring to a high run CD manufacture.
Also known as CD pressing, CD replication is a more cost effective way of making CDs once the quantity required is above 500.
The process starts with making a glass-master of the CD. This is literally a master of the disc that is made of glass.
From the glass master, a stamper plate is manufactured through a nickel plating process.
Once the stamper is made, we are ready to begin the CD duplication or pressing.
The stamper is loaded into the replication machinery, and then the machines are loaded with a plastic powder, known as polycarbonate. This plastic is raised to about 400 degrees, and then it is ready to be injection moulded to become CDs.
The data on the stamper is transferred in the injection moulding process, and the result is clear discs that are manufactured by the machinery every 3-4 seconds.
These discs then need to be metalised, which involves applying a thin layer of metal to one side which is then sealed in using a lacquer. The disc can now be played in a computer or CD player.
Usually before the CDs are shipped out, there is one more process involved which is the CD printing.
The printing can either be litho offset printing, or screen printing depending on the style of the artwork and the finish required by the client.
Benefits of CD Replication
The biggest benefit for having your CDs replicated is to do with cost. Once the quantity of CDs required is more than 500, then having the CDs replicated is cheaper than CD duplication.
The next big benefit is speed of manufacture, if the unit quantity is a large run of say 25,000 or more, then replication will be faster than duplication.
With some older CD players, there used to be a playability issue regarding CDs that have been duplicated. Where as replicated CDs would not have such a problem. However, in more recent years this does not represent such a big issue, as new CD players have the right inbuilt software to be able to read duplicated CDs.