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More About Blu-Ray Replication
Glass mastering is performed in a class-100 clean room - which is a self-enclosed clean environment within the mastering system inside. Contaminants introduced during critical stages of manufacturing (ex., dust, pollen, hair, or smoke) can cause errors errors and make a master unusable. Once successfully completed, a Blu Ray master will be less susceptible to the effects of these contaminants.
During glass mastering, glass is used to hold the Blu Ray master image while it is created and processed. Glass substrates, noticeably larger than a Blu Ray disc, are round plates of glass approximately 240 mm in diameter and 6 mm thick. They often also have a small, steel hub on one side for easier handling. The substrates are created specially for Blu Ray replication and one side is polished until it is extremely smooth. Even microscopic scratches in the glass will affect the quality of Blu Ray discs pressed from the master image, so it is important to choose a replication company that you can trust.
Once the glass plate is cleaned using detergents and ultrasonic baths, it is placed in a spin coater. The spin coater rinses the glass black with a solvent and then applies either photoresist or dye-polymer, depending on the mastering process. Rotation spreads the photoresist or dye-polymer coating evenly across the surface of the glass. The glass is then removed and baked to dry the coating.
While nearly all mastering to glass is done at multiple speeds for sake of efficiency, single speed glass mastering (also referred to as 1X glass cutting or 1x glass mastering) remains as a higher quality option. A large number of consumers believe this results in truer reproduction, although the quality loss from higher-speed runs is negligible.
Whether you're seeking Blu-Ray discs in the thousands or the millions, Flow Motion is your solution for flawless disc replication. We offer up to 6 colors of top quality silk-screen or offset printing (CMYK + W + Pantone).
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