zxing barcode reader example java Preparing the Glass Master in Software

Drawing ANSI/AIM Code 39 in Software Preparing the Glass Master

2 Preparing the Glass Master
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It s not really made of glass, but it s built on a pristine optical glass platter to facilitate movement through the creation process The actual Glass Master is a faithful bit-for-bit recording of your DVD master onto a photoresist substance mounted on the glass platter (see Fig 16-7) The Master image data are prepared by loading it into the Laser Beam recorder s playback system (Hard Disk), and a Glass Platter coated with the Mastering Material is prepared in the Laser Beam recorder The DVD image data are then written in a very precise manner onto the photo-resist material covering the Glass Platter Each Layer of the finished DVD requires its own Glass Master, which is why each layer is delivered on a separate DLT tape This is a critical step
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Figure 16-7 Preparing the Master DVD image for burning Glass Master
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4 Plating Growing the Stamper
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By repeating the process of adding metal to the existing DVD disc image, the electroplated Stamper is born (see Fig 16-10) These Stampers can be mounted into the Injection Molding machines that actually press the polycarbonate beads into DVDs Because each DVD is actually two layers of polycarbonate bonded together, each layer of data must become its own stamper, and the individual layers are created separately, then assembled according to the needs of the DVD
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Figure 16-8 Recording the Glass Master from your DVD data
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3 Metallizing the Glass Master
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Once the Glass Master has been recorded (see Fig 16-8), the next step is to create a more physically robust image of these data, to allow for the creation of the stampers If you look at Figure 16-9, you will see the metallization layer fills in the pits burned by the laser, and creates a negative image of the data on the Glass Master It also provides a surface that is far more durable than the developed photoresist material, allowing for a further layer of plating to occur in the next step
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Figure 16-10 Forming the Stamper
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5 Molding The Stamper Goes to Work
On the replication line, polycarbonate beads are injected into the molding press, where the Stampers are used to impress the final DVD data image on the polycarbonate (now liquefied) under extremely high pressure (~30 tons!) One finished DVD layer emerges from the process every 5 10 seconds, depending on the specific press used (See Fig 16-11)
Figure 16-9 Metallizing the recorded Glass Master
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Figure 16-11 Injection Molding the DVD from fluid polycarbonate
6 Sputtering The DVD Gets a Reflective Layer
Once the injection molding process has created a substrate with DVD information impressed into it, a very fine layer of metal is added to it to enhance the reflectivity of the information (see Fig 16-12) Sputtering is a process where a metallic source is vaporized, and the metallic vapor deposits onto the polycarbonate substrate
Figure 16-13 Bonding the DVD layers together
8 Labeling
For DVD-5s and DVD-9s, virtually the entire disc face surface is available for labeling, by a variety of means: Screen Print: Spot or process print as used by the CD industry One to five colors can be applied with caution Reverse Screen Print : Printing on internal surface of unused side for Wet Look appearance Offset Printing: Full color picture printing similar to magazine print Low ink mass and shrinkage is beneficial for DVD balance and tilt Flexographic Printing: New disc printing process similar to offset printing but with spot print capability Pit Art: Stamper produced for molded artwork/printing You will notice the deliberate omission of sticky labels in the above information Sticky labels are the
Figure 16-12 Plating the DVD impression
7 Bonding
Each DVD substrate produced by the injection molding system is actually only one half of a finished DVD, 6 mm in height To produce a proper finished DVD, two halves must be bonder together to produce the full 12 mm height disc (see Fig 16-13) This is how we get dual-layered DVDs
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bane of DVD authors They work fine on CDs, but are to be avoided at all costs on DVDs!
Single-layer DVS (DVD-5, each side of a DVD-10)
Single-layer DVDs include one substrate with data, bonded to one blank substrate (see Fig 16-14)
packaged in CD-style Jewel Boxes, paper or cardboard packages (as inexpensive CD shipping sleeves), and even plastic and cardboard combinations (like the Snapper package used on Warner Brothers DVDs) There are even more extravagant packaging styles available, like the crystal clear Super Jewel Box Expensive, but elegant Before you ask for a quote from the replicator, you should have a good idea of which package style you wish to use, and how you are going to have the graphics designed for it In each case, a conversation with the replicator will determine which packaging options are available through that replicator, and more importantly, what the physical printing and design specs are for each type of package
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