Manufacture
Replicated CDs are mass-produced initially using a hydraulic press. Small granules of heated raw polycarbonate plastic are fed into the press. A screw forces the liquefied plastic into the mold cavity. The mold closes with a metal stamper in contact with the disc surface. The plastic is allowed to cool and harden. Once opened, the disc substrate is removed from the mold by a robotic arm, and a 15 mm diameter center hole (called a stacking ring) is created. The time it takes to "stamp" one CD, is usually 2 to 3 seconds.
This method produces the clear plastic blank part of the disc. After a metallic reflecting layer (usually aluminum, but sometimes gold or other metal) is applied to the clear blank substrate, the disc goes under a UV light for curing and it is ready to go to press. To prepare to press a CD, a glass master is made, using a high-powered laser on a device similar to a CD writer. The glass master is a positive image of the desired CD surface (with the desired microscopic pits and lands). After testing, it is used to make a die by pressing it against a metal disc.
The die is a negative image of the glass master: typically, several are made, depending on the number of pressing mills that are to make the CD. The die then goes into a press and the physical image is transferred to the blank CD, leaving a final positive image on the disc. A small amount of lacquer is applied as a ring around the center of the disc, and rapid spinning spreads it evenly over the surface. Edge protection lacquer is applied before the disc is finished. The disc can then be printed and packed.
Manufactured CDs that are sold in stores are sealed via a process called "polywrapping" or shrink wrapping.
Read more about this topic: Compact Disc
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