SINGULUS TECHNOLOGIES (SINGULUS), the world’s leading system integrator of optical disc replication equipment, has successfully introduced its inline manufacturing solution for Blu-ray Disc (BD), the BLU-LINE.
The BLU-LINE system includes all production steps from molding, sputtering, lacquering/bonding and UV-curing to hard-coating and testing. Its functionality, speed and design will set a new benchmark for the industry. The BLU-LINE embraces all the advanced features required for production of high end BD. Within a very compact footprint, all important process steps are integrated under a cleanroom 100 environment. No extra control cabinet is required and all parts are incorporated into the machine body. The SINGULUS BLU-LINE is designed according to the specifications issued by the Blu-ray Disc Association, and provides excellent maintenance and service accessibility.
The BLU-LINE was specifically designed to deal with any kind of cover layer technology and to provide stable product quality over the entire production run. The BLU-LINE design can accommodate two different methods of applying the 100 micron cover layer on BD; one machine version uses film bonding technology, while the other system is dedicated to liquid resin technology. Each layer requires optimized hardware and software to achieve the proper process conditions. SINGULUS has prepared special modules for sputtering technology, cover layer technology and hard-coat technology. The arrangement of the cover layer module can easily be altered between laminated film and liquid resin technology, when process or cost modifications demand reconfiguration of the system.
The BLU-LINE operates with one molding machine. SINGULUS has qualified its new MoldPro All-Electric Molding Machine for BD production. There is an optional barrier coating module that can be integrated to deposit a moisture barrier with a protective layer on the label side of the disc.
In addition to optimizing the current process workflow, SINGULUS is intensively developing an optional dual layer module which can be integrated with the BLU-LINE in order to manufacture Dual Layer BD with a capacity of 50GB.
The first BLU-LINE systems were delivered to key customers in the US during the fourth quarter of 2005. In February, SINGULUS installed two more lines with international customers. This makes SINGULUS the only European manufacturer to place BD replication lines in test production with five major clients.