After premastering is complete the manufacturing process can then begin.

Mastering
Mastering is considered the most critical step in the manufacturing process. Very tiny microscopic CD pits are created in the mastering process which needs to occur in a clean room environment.

There are several methods available for CD mastering though photoresist is the preferred method. This method produces what is called a glass master by applying a light sensitive chemical to a glass substrate. Data is recorded in the photoresist layer through a laser where a computer translates the formatted input media into a series of "on" and "off" pulses. In a spiral track, the laser beam recorder exposes portions of the photoresist with a blue light, creating the disc contents. Similar to a photographic process, the glass master is completed by applying a chemical developing fluid. The exposed areas of the photoresist are etched away resulting in the formation of millions of microscopic CD pits on the surface.

Creating Stampers
The next step is to generate a metal stamper which can then be used to replicate the CD, this process is referred to as Electroforming. In this stage of production the glass master is sent through a chemical process. The end result is the formation of a durable piece of nickel plating containing a negative impression of the compact disc in its metallic surface. This initial piece is known as a metal master or "father". This master is then used to create an additional pieces of metalwork called a mother which is then used to create a final metal master called a stamper. The stamper, an exact replicate of the metal master, is the end product of this stage of production and the template from which plastic CD replicates can be mass produced.

Mass Production
The first step in replication is to transfer the image of the compact disc from the metal stamper to a plastic substrate. A high-precision injection molding process, which only takes a few seconds results in a clear plastic disk. This disk is then metalized which gives the CD its shiny reflective surface. Finally a protective coating is applied.

Printing and Packaging
Graphic images are applied to disk via silk screening or offset printing. Depending on your the equipment involved as many as 8 colors can be reproduced. Silkscreening is the most popular though offset printing provices the ability to produce enhanced color images to the surface. After printing, discs are either automatically or manually packaged into a wide variety of alternatives such as the plastic CD-ROM cases.

Turnaround Time
Turnaround time is the time it takes for a replication facility to complete all the stages of CD-ROM production The faster the turnaround required for finished product, the more expensive the service. Rush jobs, such as one- and two-day turns, are available but at significantly higher costs than standard seven-day turns, with premiums varying among manufacturers.

Summary
Although disc manufacturing is a standardized process, the quality of your total CD-ROM production experience, including flexible scheduling, technical expertise and one-stop-shopping to name a few, can vary greatly from company to company. Finding the right long term partner to meet your requirements is a task which involves research beyond basic price comparisons. Please contact Netmation when considering a CD-ROM production project.