DVDs spur resin & machinery advances.

Industry has been talking about it for the last three years, and finally "DVD" is here. At June's Replitech International trade show in San Jose, Calif., digital video (or versatile) discs were the main topic of discussion and also the target of much of the newest disc replicating materials and equipment on display.

Commercialization of the new format is just getting off the ground. This spring, some of the major film studios announced their commitment to the new format. DVD players (available from 10 manufacturers) made their debut early in the year, and some software titles hit the streets in March.

According to industry sources, 200,000 DVD video players have been shipped to market, along with 600,000 DVD video discs. That number may seem small, but titles are available only from three firms: Warner Home Video, Polygram, and Columbia Tristar. Universal, Fox, and Disney have not yet committed to DVD format. Also, Warner titles are available only in a test market of seven cities.

Disc makers also say the DVD-ROM sector has begun to heat up, although few software titles have yet appeared.

MANUFACTURING CHALLENGES

About 11 replicators are in stages of DVD start-up, though only three of them are actually sending discs to market. A DVD is made up of two 0.6-mm-thick substrates bonded together, each half the traditional 1.2-mm thickness of a conventional CD. Disc makers caution that producing DVDs can be "a bear" if the replicator lacks experience and the right equipment. Just because a machine can produce a CD does not mean it can produce a DVD. Equipment upgrades are available to retrofit existing CD systems, but most industry observers advise buying hardware designed specifically for DVD.

Presses for DVD molding aren't all that different from CD machines, except that they have dedicated DVD tooling, injection-compression (coining) capability, and high-end controls needed to produce the thinner substrates and hand them on to the downstream equipment. Press makers often quote cycles under 4 sec, but such figures don't mean much without specifying quality yield.

DVD manufacturing is quite an expensive proposition. A single line can produce perhaps 20 million discs a year, but replicators are very secretive about actual production rates. Some sources estimate that a minimum of about $2.5 million investment is needed to get going. Mastering services cost even more.

If you can get past the difficulty of authoring and mastering a disc, the molding part might be relatively easy. But bonding the two 0.6-mm discs is tricky, replicators say. It is not simply gluing two discs together. Three techniques exist, but replicators and machinery manufacturers admit that none is perfect.

In addition, it is important to note that there is little test equipment available for the new format. Best known are systems from Pulstec Industrial Co., Ltd. of Sizuoka, Japan. They are not only extremely expensive (around $200,000-250,000) but also hard to come by. As noted below, Pioneer has just come out with a tester for half that price.

ENHANCED DISC RESINS

Four major producers of polycarbonate have introduced new grades for DVDs. All offer higher flow than standard disc resins to control birefringence and dishing and to ease replication of the smaller and more closely placed pits in the thinner discs.

* Dow Plastics, Midland, Mich., made its entrance into the optical-disc market with Calibre 1090 DVD. Its MFR is 80 g/10 min.

* GE Plastics, Pittsfield, Mass., has new Lexan OQ1030L with MFR 10% higher than that of existing Lexan OQ1020L. This month, GE also begins installing two 30- and 40-ton presses for a new Optical Media Development Center in Pittsfield.

* Bayer Corp.'s Polymers Div., Pittsburgh, launched Makrolon DP11265 with an MFR of 80.

Bayer also introduced what it claims is the first system in the U.S. for bulk delivery and storage of CD-grade PC resin. The system was developed for CD maker Sonopress in Weaverville, N.C, which wanted to avoid the inefficiencies of handling standard 1500-lb bags. The solution was a specially modified bulk trailer that is sealed and pressurized with HEPA-filtered air. Resin is conveyed from the trailer to silos using all-stainless-steel pneumatic equipment from Motan Inc., Plainwell, Mich.

* Teijin Chemicals Ltd. of Japan has improved its resin for DVD. Called Panlite AD-5503X, it has higher purity and heat stability and excellent mold release, according to Teijin. U.S. office is Teijin Kasei America, Inc., Atlanta.

LATEST DISC MACHINERY

Krauss-Maffei, Corp., Florence, Ky., developed the KM80-190 CD-HD machine specifically for DVDs. It's a hydraulic, two-platen unit with simultaneous accumulator-assisted injection and coining functions. Reproducibility is accomplished through precise screw positioning in coordination with clamp-force build-up. This machine ejects the discs during the 8-mm mold-opening stroke. With the mold open, the sprue is retracted and a venturi vacuum eliminates any fragments.

Krauss-Maffei also showed its DVD hot-melt bonder with a 3.9-sec cycle.

Toshiba Machine Co., America, Elk Grove Village, Ill., introduced a 45-ton DVD machine, model IS40HD. A "moment-free" mechanism that maintains equilibrium between injection and clamping pressures is said to eliminate disc center bending and stress. The robot has a 0.15-sec take-out time. Toshiba also has new TiN-coated DVD molds with four temperature-control circuits and high-speed stamper-changing capability.

Model MO40D3H (46 tons) is a new dedicated DVD machine from Nissei America Inc., Anaheim, Calif. It features increased clamp rigidity and tighter temperature control ([+ or -]1 [degrees] F). Coining action reportedly has time and position control to 0.001 sec and 1 micron.

Toolex Alpha Inc., Columbus, Ohio, is offering its High Density Moulder (HDM) for DVDs or standard CDs. It includes a new servo-driven robot.

Toolex Alpha also has a DVD monoline system based upon its FI-FO disc replication system. A new mold design and improved injection techniques reportedly make it suitable for DVD.

Also new from Toolex is the MD100 press for molding CDs and 80-mm mini-discs. It boasts a servo robot, faster controller with improved closed-loop software, and an easily adjustable punch unit.

Arburg Inc., Newington, Conn., has a new DVD machine based on its S-Series 28-ton press, whereas earlier CD systems used a 40-tonner. It uses a mechanically driven robot with a 0.15-sec cycle and a new twin-cavity DVD tool from Axxicon Molds, Norcross, Ga. That tool produces the A and B substrates under identical molding conditions. Arburg claims a 7% reject rate at 3.8-sec cycles.

The Fanuc Roboshot 50E all-electric injection machine specially modified for DVD and CD-ROM is offered as part of a complete production line by Data Disc Robots, Wuerselen, Germany. (Robotshot machines are sold separately by Cincinnati Milacron Plastics Machinery Group, Batavia, Ohio). With 3.8-sec cycles, it's said to provide disc yields of 98% to Red Book specification.

Technoplas USA, Inc., Columbus, Ohio, introduced a standard mold design for all disc formats. The new mold, called Disk-ZR, reportedly has improved release, lower maintenance requirements, and zero-tolerance linear bearings on guide pins, punch, and sprue ejector.

Sumitomo Plastics-Machinery, Norcross, Ga., introduced an H-Type mold designed for the current DVD-9 format and for the firm's SD30 disc-molding machine. The inner diameter of the stamper holder is only 22 mm, rather than the usual 34-37.4 mm. Despite the small inner diameter, a new cooling-channel design reportedly provides consistent and low birefringence around the center hole. To eliminate flashing around the hole, the H-Type mold has a mechanical center holder instead of a vacuum stamper holder.

First Light Technology, Inc., Saco, Me., demonstrated its Unijet monoline system with a Netstal Discjet 600 molding press. The Unijet reportedly can run at less than 3.0 sec/disc depending on quality criteria. First Light also now offers its Dual Cathode Metallizer for sale separately.

Marubeni America Corp., Southfield, Mich. (U.S. representative for Meiki injection presses and Origin uv lacquer bonders), introduced The UV Flashlight DVD Bonder. The system reportedly cuts lacquer cure time substantially without raising the disc temperature.

Optical Disc Manufacturing Equipment (ODME), Veldhoven, Netherlands, released information on its new Direct Stamper Recording system, which will be shown for the first time at Replitech Asia in November. Designed for short runs of all optical formats, this mastering equipment uses a new 300-mm-diam. blank nickel shell that is supplied ready for recording. ODME also showed its Miniliner monoline system for CDs and DVDs and its uv bonding system for all DVD formats. U.S. office is ODME USA, Charlotte, N.C.

Leybold Technologies, Enfield, Conn., showed its DVD Speedline Plus/Arcadia monoline system with a reported cycle time of 2.8 sec and output capacity of 22,000 discs/day. Leybold also showed its Apollo uv bonder for DVDs.

Multi Media Masters and Machinery of Yverdon-les-Bains, Switzerland, unveiled the MCL 100C, a "one-box" system that integrates all molding and finishing steps and controls. U.S. office is Multi Media Machinery Inc. Americas, Minneapolis.

Pioneer Video Corp. introduced its fully integrated DVD replication unit, called the "Mars" system, which combines two injection machines, a sputtering unit, two overcoaters, and a uv cationic bonder into a single line. By changing the molds (designed by Pioneer Video), this machine can also produce CDs and CD-ROMs. Mitsui Plastics, Inc., Atlanta, distributes Pioneer's DVD equipment.

A new signal inspection machine from Pioneer measures DVD electrical parameters at half the price of competitive machines.

Robi-System Inc., Cherry Hill, N.J., introduced the highly compact Solitaire monoline system for all types of CDs and DVDs.

Trace Optical, Avon, Mass., has upgraded its Optiline replication system with a faster metalizer that also permits faster target exchange. The spin coater also has been, updated. Trace offers an interface to Sumitomo molding machines.

Trace Optical also introduced Optilock, an off-line, dual-lane bonder for any DVD format. Cycle time is said to be 3 sec.

Singulus Technologies, Windsor, Conn., showed its new Spaceline turnkey line for all DVD formats.

PRINTING EQUIPMENT & SUPPLIES

Majestech Corp., Somers, N.Y., introduced a line of laser-cut CD screen-printing frames plated with a permanent zinc treatment to provide extended wear. Also new is C-Flex rubber-toughened cyanoacrylate frame adhesive that is said to be more flexible than conventional cyanoacrylates.

Dubuit of America Inc., Niles, Ill., exhibited the model 438, which screen prints up to three colors at speeds up to 5400/hr. When used with the firm's screen-alignment system, a job reportedly can be set up in minutes using relatively few discs.

Kammann Machines Inc., USA, St. Charles, Ill., introduced a system that allows quick set-up of its screen printers while using only one disc per color and around 15 sec per station.

Autoroll Machine Corp., Middleton, Mass., introduced the Rotoflex 560M screen printer for CDs. New all-mechanical drive, automatic screen alignment, and forced screen breakaway are said to increase productivity and print resolution while simplifying operation and reducing maintenance.