Replication

The BD replication process begins with polycarbonate substrate moulding, which contains data that is made up of the pits and lands, and is followed by sputtering the reflective layer followed by . a base spacer layer which goes on for the pit transfer layer, then the Layer 1 data layer is embossed before another reflective layer is sputtered. After that the UV-cured resin cover layer goes on, then the hard coat layer, which is necessary because the Blu-ray Disc data layer is closer to the surface and more vulnerable to scratches. Finally the metalised moisture barrier layer is applied to prevent warping of the disc.