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Sony’s Blu-Ray Factory

Thursday, July 30, 2009

 Bluray-amarjits

Rounds to flats ... each Blu-ray disc begins its life as a collection of small polycarbonate granules delivered to the factory by truck and stored in a silo.

Bluray-amarjits (3)

Clean room ... to reduce contamination, technicians must enter the production room through a chamber that blasts loose dust off their bodies with air jets.

Bluray-amarjits (2)

Go with the flow ... the polycarbonate granules are piped around the factory until they arrive in this hopper above the moulding machine that measures them out evenly.

 1

Under pressure ... the mould compresses the melted plastic into a disc and creates the first layer of data. Then the disc is removed by a robotic arm for the next step

2

Shiny ... the disc is then coated in a vaporised layer of silver 90 angstroms thick, in a process called sputtering. An angstrom is one 100 millionth of a centimetre. The electromagnetic field around the sputtering machine is so strong that it affects pacemakers

3

Toward the light ... the sputtered disc is then coated in a layer of UV resin and cured with light, before moving on to have the second layer of data embedded.

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Under observation ... Sony Digital Audio Disc Company (DADC) technicians monitor of the of three Blu-ray machines. In full production, each machine can make up to 16,000 discs a day.

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Hard layer ... finally, the disc is given another coating of UV resin and a final protective layer before being checked for any tiny bubbles between layers by this machine

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Runtime ... the final stage of the production process is to check the data integrity of each disc through playback and scanning

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All made up ... the discs, having been checked for errors, are then loaded into the printer that will add the artwork to their surface

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Master plates ... the artwork for every disc printed at the Sony plant is stored in this rack, ready to be loaded into the printer for another run

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Silkscreen-style ... the artwork is broken down into black, cyan, magenta and yellow layers that are applied separately, building up to the final image which is blasted with ultra-bright light to set the ink

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Insert here ... the finished discs are then taken to the assembly packing line where they are matched with a plastic case, cover and any inserts

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Flip and close ... the assembly packing line places the disc and insert into the box. At full production the machine can package 4500 Blu-ray discs per hour. The discs now start going out to retail stores all over Australia. About two thirds of them are films and the rest games. Source: Somewhere from the internet.

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