Replication, the mass manufacture of cd and dvd discs, requires large quantities to be cost effective and also requires a turnaround time that is unacceptable to many on-demand applications. Many organizations and companies choose DVD ROM duplication to effectively distribute information and content. Compared to replication equipment, DVD ROM duplication equipment is inexpensive and easy to operate.

The typical DVD purchased at the store is a 'replicated' disc. That means that it was sent to a plant that created a glass master and then used that glass master to physically impress the information in the plastic during the disc manufacturing process.

A duplicated DVD, though it appears the same to your computer, was fully manufactured before the information was prepared. The data is recorded to the disc by laser into a dye that lies above the substrate (the plastic bottom of the DVD) and the reflector (the shiny layer that sends the modified laser signal back to the ROM device). It is fairly easy to tell if a DVD has been duplicated or replicated, as duplicated DVDs have a colored bottom side, due to the purple or brown colored dye below the reflector. In addition, a replicated DVD supports up to 19GB of recorded data, while a duplicated one has a limit of 4.7 GB per recorded side.

If you are currently using an outside provider for your DVD ROM duplication services, you may want to consider doing it yourself. As with all in-sourcing, this decision should be based on break-even analysis (how soon will I save the cost of the equipment purchase) and consideration of your other resources. (Do I have the time/knowledge/desire to do this myself).

With the advancement of DVD ROM duplication technology, it is becoming practical for more and more businesses to bring their DVD ROM duplication in-house. Much like photocopying paper, DVD ROM duplication can be as simple as simply placing your master copy and your blank media into the machine and pressing a button. Some questions your DVD-Duplication specialist will ask you are: How many DVDs are you doing at a time? How often are you doing that size of job? Do you need to print on/label the DVD? Give us a call at 800-646-8881 and we can help you through the steps.

 

PC-Attach vs. Standalone
	DVD ROM duplication can be done standalone (without the aid of a computer, like a photocopier) or PC-Attach (like a network printer). Neither system has an advantage from a quality standpoint, but their usefulness differs greatly depending on what the user is trying to do. In an environment where many different discs are being made, particularly by multiple users, A PC or Network attach machine makes sense. It enables each job to be created individually and custom parameters set, including merge fields, individualized labels, and so on. On the other hand, if many copies of a single disc are being made, Standalone makes sense. Standalone removes the idiosyncrasies of computers from the equation, and is also friendly to novice or untrained users. Often Churches, Schools, and large-run duplication houses rely on Standalone duplicators to fill their DVD ROM duplication needs.
Recording Speed
	Recording Speed determines the potential throughput of your DVD ROM duplication system. The recorders themselves, contained within the system, record at a maximum speed of up to 52x (CD) or 4x (DVD). With future technology improvements, it is expected that the maximum speed of DVD Recorders on the market will increase in the next year. Throughput is generally measured in discs per hour. For example, a full 4.7 GB DVD being duplicated at 4x takes 15 minutes to burn. Divide the number of minutes in an hour (60) by the number of minutes record time (15) and you get 4 discs per hour. Now multiply that by the number of recorders in the system, and you will have the output capability of your DVD ROM duplication system in discs per hour.
Robotic Types
	There are two types of automated solutions on the market. Those that grasp a disc and move it around using a robotic arm are called pick and place. Benefits of this type of system include the ability to handle different sizes of media. Besides the standard 120 mm round disc, many companies' duplication requirements include the ability to do 'Business Card' cds, 'mini' cds, or 'hockey rink' cds and other custom shapes. Templates can be built for some DVD ROM duplication machines that allow the robotic arm to work with these novelty discs. The other type of duplication is called 'gravity-fed'. A single moving part dispenses discs to the recorders and readers in the DVD ROM duplication unit. Advantages include reliability due to minimal moving parts and improved throughput speed in reloading the discs. In the picture on the left, the upper left machine represents pick and place robotics, the lower right gravity-fed. Both types of machines can be found at www.microboards.com.

Printing

There are also two main methods for printing on a DVD. Thermal Printing uses a wax transfer ribbon and a heated print head to transfer a design to lacquer or ceramic coated media. Advantages of this method include the durability and water impermeability of the print, as well as having a nice professional finished look. Inkjet Printing uses ink in a similar manner to paper printing. An inkjet printer head applies ink to a disc with an ink-receptive surface. Advantages to inkjet printing include higher-resolution, more vibrant images, as well as lower startup costs. Both types of printer can be found at www.microboards.com. In addition to these two methods, persons with higher volume requirements often use 'silkscreen' printing to do large runs. Advantages include a combination of high resolution and durability. However, setup costs for this are considerably higher unless discs are being done in quantities of thousands at a time.

CD Duplication | DVD Duplication | Rimage | CD ROM Replication | DVD ROM Replication | CD ROM Duplication | DVD ROM Duplication