Vasopato DVD Replication

Gary: This is Barry Brovold. He is a stamping engineer at Imation, and Ted
sends his regards, and he also sends this finished master.
So what do you do with it?

Barry Brovold: Oh, thank you. What we do with the master now is we have a
proprietary process that we can duplicate the image of this
onto another surface, that being with photopolymer onto a
plastic, and what we will come up with after that is
something that looks like this.

Gary: It is a mirror image of the master.

Barry Brovold: It is a mirror image of the master.

Gary: So from here it goes into a mold?

Barry Brovold: Yes, it goes through the molding process where it can make
thousands or hundreds of thousands of duplicates.

Melinda Weber: Hi, Gary.

Gary: Hey, Barry sends his best, and he also sent over this stamper. I am
just curious, what do you do with this from here?

Melinda Weber: Well, we take the stamper, and Doug here, he installs it
into the molding cavity. Once we have the stamper in place,
we take a molten polycarbonate and inject it into the mold.
In there, it then takes the exact replica of the features
from the stamper and puts it onto the substrate. Once we
have our substrate, we then need to put some sort of a
recordable layer on the disc.

One method is thin film coating. The machine next to me
does thin film coating as well as DVD replication. It can do multiple layers based on
what product we want to make, whether it is Blu-ray or HD
DVD. There are different layers put on in different order
based on whatever the product needs are.

Another method for putting on a recordable layer is spin
coating. In spin coating, we put a recordable dye on the
disc, and then using centrifugal force, we spin it out.

The next step in the process is a metallization process. In
that process, we use sputter coating to put a thin layer of
metal onto the disc for reflectivity.

Now that we have our coated discs, the next step in the
process is bonding. For bonding, what we are doing is
taking the disc, and we put a thin layer of adhesive on
with the spin-coating process. After that, we take a dummy
disc and we place it precisely on top of the coated disc
with the adhesive on it. Once it goes into the vacuum
chamber, all of the air is removed.

The next step is to go into the UV cure. For HD DVD discs,
after the disc has been bonded, we now have the recording
layer sandwiched in the middle of the disc. For Blu-ray,
the recording layer is sitting just below the cover layer,
which is very close to the surface of the disc.

Some discs require initialization. Initialization process
is where a laser crystallizes the recording surface of the
disc. The crystallization process converts the recording
layer of the disc, allowing it to be written to by the
laser in your drive.

Jim Milligan: What makes the blue optical technology uniquely different
from other formats is the capacity, random access
capability, and volumetric storage capability of the media
along with the open format and the fact that it is a
standard format. It just represents a tremendous
opportunity for professionals and businesspeople for
storage.

Terry O'Kelly: That capacity can be used for video, for example with the
new high-definition camcorders that are coming, or set-top
recorders in the future that are going to be recording high-
definition programming from either cable or over the air.

Jim DePuydt: We are in a good position to lead in this area because we
have been involved in optical technology for more than 25
years. We were there when video disc was created, and we
have been involved in optical since that time until the
present, and so we understand optical disc technology like
. . .

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