CD and DVD Printing –- Choosing the Best Print Method for Your CD or DVD Duplication Job

When it comes to CD & DVD Printing nowadays there is so much choice that unlike paper printing (where run size and cost are the main factors), you’re faced with the daunting choice of Litho, Screen, Inkjet, Digital and Thermal printing on CDs and DVDs or even a combination of 2 or more of these. DVD duplication is fairly simple - the data is either there (and works!) or isn't. The print on your duplicated DVD or CD is what will set it apart from the millions of other discs out there.

So how do you determine what is best for your run of CDs or DVDs?

As a basic guide, stick to the following principles; solid colours should be screen printed, as should Pantones. CD & DVD artwork consisting of photographs or CMYK mixes with lots of graduations and tints will look better litho printed or better still printed using the new generation of UV cured CD and DVD printers. One of the best examples of this new print process is a new printer developed by Sun Chemical; its resolution, vibrancy of colour and gloss finish gives picture discs an almost 3D feel to them.

Screen printing requires the artwork to be split up into constituent colours. A film is then exposed from each of these colours (usually including a white base). From this film a screen is made; this is a 12cm square porous mesh with the area not to be printed remaining as a non permeable area. Ink of 1 colour is forced through this mesh with a rubber blade (known as a squeegee), onto the surface of the disc. Screen printers can have up to 5 colours, applied one after the other. Once the ink has been applied the disc is passed under a powerful UV lamp that cures the ink, solidifying it. This method allows for some creativity, such as not applying ink in some areas, revealing the silver disc layer beneath, or applying special varnishes to give specific areas of the disc high gloss or conversely a matt finish.

Litho printing also starts with photographic exposure used to generate plates. In litho (also more correctly known as offset) the print is made up of 4 colours; cyan, magenta, yellow and black (CMYK), also usually on a white base.Artwork is separated into these constituent colours and from the exposed films 4 plates are made. This ink is applied to these and rubber rollers then pick the ink up, reapplying it to the surface of the disc. Once the 4 colours have been sequentially applied then the disc is also cured under a strong UV light.

The latest generation of Digital disc printers use UV cured ink and multiple print heads that are similar to consumer inkjet but on a much bigger scale. Each colour is applied by 8 separate heads which dramatically increases resolution and variable droplet size allows greater variation in shades. A digital printer such as this will print 1200 discs per hour compared to a consumer inkjet’s 30 or so. Once the ink has been applied to a white base it passes under a UV light to be cured into a solid, glossy and durable finish.

Inkjet and Thermal print offer a cost effective solution for very small runs of full colour printed CD & DVD and the lead time is normally a matter of hours rather than days, though this of course depends in the size of the duplication facility.

Inkjet printers use the same technology found in consumer printers, with a modified caddy to take a disc and sometimes automated disc loading and unloading.

Thermal (or thermal transfer) prints the image using a colour film that is applied using a high temperature process. This is a particularly expensive and inefficient way of printing discs as there is a lot of waste film from the areas of the disc that is unprinted. It is also a very slow process.

Solid colours and pantones should be avoided printing with either of inkjet or thermal as pantones will be difficult to match and solid colours will exhibit banding or lines.

A professional duplicator will be able to not only offer any of these methods but more importantly be able to advise on which of these methods is the best for your artwork.