CDs are created from raw polycarbonate plastic in an injection molding process. We start with pure 100% virgin optical grade polycarbonate. The polycarbonate pellets are dried thoroughly to remove any trace amounts of moisture before they enter the injection molding machine (IMM). In the IMM, they are slowly heated until they melt and form a liquid.

This liquid is forced under enormous pressure into the mold that forms the disc. The mold contains a metal stamper that is a "negative image" of the encoded digital data that will be molded into the disc as a microscopic spiral track of pit and land surfaces. After the plastic cools and hardens for a moment, a robotic arm removes it from the mold. The clear plastic disc is automatically transferred to the M2 SQ1 Compact Disc Production Machine. Here the disc is carefully cooled to maintain its perfect clarity and shape. Once cool, the disc is transferred by robotics to a vacuum chamber where the reflective aluminum coating is sputtered onto the polycarbonate substrate.

It is then transferred to a spin coater that applies a protective layer of lacquer to protect the aluminum. The disc is passed under an ultraviolet light to cure the lacquer. The final step is an optical inspection for physical imperfections before it leaves the finishing unit. Discs are produced at the rate of approximately one every 3.5 seconds.

The completed discs are now ready for printing. We print on the discs using a silk screening process. The screens are created from your color separated artwork. Discs can be printed using up to 6 colors including a white flood. Both Pantone Matching System (PMS) colors or four color process (CMYK) or a combination can be silk screened onto the silver disc or a white flood background. Each print head of the AutoTec 3120 prints a single color and is cured by ultra violet light before it moves to the next print station. Our press prints at a rate of 80 discs per minute with an accuracy of +/- .0025mm. The finished discs are compared to a proof for color accuracy.

After printing, the discs are ready to be packaged. There are numerous options for packaging CDs. The most traditional option is the jewel case. Our automated packaging equipment can assemble the discs into a jewel case with a front insert and back tray card. The finished cases can then be placed in our automatic shrink wrapper to give your project that professional touch. Another popular option is a custom printed pocket sleeve. This item has a pocket on one side to hold the disc with another panel that folds over. There are also many types of generic sleeves available in Tyvek and cardboard, with windows and without. Discs can also be spindle wrapped. After packaging, the discs are ready for shipping or delivery. We can ship worldwide using many carriers. We can deliver them to your location, or you may come to our facility and pick them up.