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Shaped CD Replication
Shaped CD Replication is the same as CD replication. CD replication is a method of CD production that Home Run uses when your shaped cd project does not have a quick turn time and the quantity can be produced for less than CD-R duplication. Other companies will stretch the limits to produce your project via CD-R duplication because this is the only CD production method available to them. Home Run will offer you the best combination of production methods to complete your shaped CDs or shaped mini CD project, because we do it all.
The most common CD shapes are:
Business Card (capacity of ~ 50 mb) (rectangular)
Hockey Rink (capacity of ~ 50 mb)
3" Mini CD (capacity of 180 mb)
Shaped CD Replication is the ideal cost-effective solution for larger runs of shaped CDs (1,000 + units). The standard and most economical turn time is approximately 7-10 days. We do offer quicker turn times. CD replication is slow to get started but fast for large quantities. This speed is achieved by physically stamping the information into polycarbonate granules in a mold. A glass stamper or mold is created from your original master. In the molding process, liquid polycarbonate is injected into the mold to form a plastic disc. Once the discs are molded, a micro-thin layer of aluminum is used to coat the discs, giving the disc its characteristic silver color. The injection molder will stamp a CD in about 4 seconds. This is really fast. But to use an injection molder a stamper containing the information must be created. This entails making a class master, a father, a mother and then a stamper. This process takes time and is expensive. So shaped CD replication is used when a large quantity of shaped CDs are needed and the time is available to make a stamper.
Silkscreen shaped CD Printing: Silkscreening is the most common technology used for decorating discs. The process begins by outputing film from electronic artwork, 1 for each color used. These films are then used to transfer the image to a screen that will be mounted to the press. The screens will have holes left open where ink should be applied and plugged where there is no printing. There are 5 screens placed on the machine (1 for white, and one for each of the colors used in 4 color process printing: cyan, magenta, yellow & black), and they sit above a rotating tabletop that has slots to hold the discs. The operator will then add the appropriate ink to the screens. This ink is then pressed through the holes in the screen by an automated squeegee and onto the disc below the screen. The tabletop will rotate to move the disc under a UV drying lamp, and then onto the next color station. We can print up to 5 colors plus a white flood coat per disc.Silk-screening is used for artwork that is colorful or where many units are going to be produced. (250 – 10,000,000).
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