DVD Glass Mastering

World Media Group creates all of its CD and DVD “stampers” in our Indianapolis Glass Mastering facility.  Stampers are created in controlled, clean-room environments ensuring the highest quality masters.  World Media Group produces all of its stampers on a swiss made Singulus AM Master that is operated by licensed technicians with over 39 years combined experience.  Additionally, World Media group maintains an EPA certified in-house waste water treatment facility to recylce and treat the liquid by products generated during the process.

The process of glass mastering is the same process used to create vinyl records.  The process involves state of the art equipment, well balanced-chemical solutions, and high level expertise.  Below you will find a more technical explanation of CD and DVD Glass Mastering process.

Glass Mastering:

The process begins with the AM Master cleaning a 180mm glass with de-ionized (DI) water and brush. Contaminants introduced during critical stages of manufacturing (dust, pollen, hair, or smoke) can cause sufficient errors, making a master unusable. Our entire glass mastering process takes place in controlled clean rooms to ensure the highest level of quality. Adhesion promoter (diamino silane) is then applied and spun dry. Photo resist is applied and then spun to the desired thickness. The glass is then placed on a heat plate for baking. After the glass has cooled, it is placed onto the Laser Beam Recorder for pit structuring onto the sensitive photo resist layer.

DI water is applied in order to wet the photo-resist, and the developer (sodium hydroxide) is dispensed. Upon the completion of the development stage, DI water is again applied to rinse all developer from the glass. After drying, the disc is placed into the sputtering chamber and sputtered with nickel. The nickel coating is used for conductivity during the electroforming process.

Electroforming Process:

During this process, an electrical current is applied to the back plate and nickel is then applied during a 10-step program process. Upon completion, the back plate will de-submerge from the nickel sulfamate solution and drain back into the electroforming tank. After another DI Rinse, the electroformed part is ready for removal from the glass. After removal, the plate is placed into isoprep (sodium hydroxide) for cathodic cleaning. The polarity is then reversed before anodic cleaning or passivation.

Stamper Finishing:

The stamper is first coated with clear tape for protection. After taping, it is ready for backsanding. The stamper is placed into the backsander vacuum plate and sanded lightly to remove any electroforming defects and given a uniform sanding pattern for molding. After another thorough cleaning, the stamper is placed into the punch machine and aligned. When the punching cycle has completed, the stamper is ready for testing. After testing, the molding process may begin.