FAQs - DVD Replication

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  • Can I order less than 500 DVDs?

    The minimum order size for DVD replication is 500 units.  However, with our Fast Tracks service, there is no minimum.

  • What is your turnaround time for DVD replication?

    Once you approve your artwork, it typically takes 12 to 15 business days to complete a replication order.  “Business Days” means you can’t count weekends or holidays. Turn time can take longer if you’ve ordered add-ons such as special coatings, embossing, etc. or have special packaging requirements.

    If you have a tight deadline—talk to us. It is usually possible to rush a job, though this usually adds to the cost of running your job.  We can also drop ship and express ship portions of your order as needed.  Don’t forget that we offer 1, 2 and 5 day turnaround time through our Fast Tracks short run duplication service.

  • What master formats do you accept for DVD replication?

    For DVD, we accept DLT and DVD-R. See our mastering specs for more details.

  • How are CDs and DVDs different?

    Though a DVD (Digital Versatile Disc) looks like a CD, it is actually two “half-discs” bonded together. It can contain data on one or both sides (dual-layer). Because of smaller pits and lands, as well as dual layers, DVDs can hold 7 to 25 times more information than a CD.  DVDs can hold cinema-like video, better-than-CD audio, and computer data.

  • How do you replicate a DVD?

    The replication process for DVD is essentially the same as that for CD, except with much closer tolerances and some extra steps. There are also some differences depending on the type of DVD disc being made: DVD-5, DVD-9, DVD-10 or DVD-18.

    All DVD discs are made of two parts, each half the thickness of a CD; that is, each part is 0.6 mm thick. The two parts are bonded together, producing a disc as thick as a CD (1.2mm). Thus, two pressings are needed to make one complete disc. DVD-5 and DVD-9 discs, which have data on only one side, consist of one part with data and one blank part.

    DVD replication begins with a flat glass disk covered with photo-resist material. As the disc spins, a laser beam modulated according to the information on the DVD-R or DLT tape “writes” the data onto the disc by creating chemically-etched pits. A series of stampers are then electroplated.

    Melted plastic is poured over the stampers and allowed to cool. (As compared with a CD, DVD discs need a shorter plastic-injection time and a higher molding temperature.) The disc is then finished by applying a reflective layer, protective lacquer, and labeling.

    DVD-9 and DVD-18 discs contain data in two layers; one of the layers is semi-reflective, allowing the playback laser to read the data on both layers in sequence. Both layers are read by a laser from the same side.

  • Do your DVDs work for both PAL and NTSC?

    We replicate DVDs according to the specifications on the original master. DVDs can be authored for either PAL or NTSC, and can be encoded for region 1-6 (or any combination). We replicate both PAL and NTSC, and for all regions, so it’s up to you and your authoring technician to supply us with your preferred format.

    Here are two useful sites to help you determine DVD formats and DVD regions for other countries.


  • What is the maximum capacity of a DVD?

    DVD-5: 4.7 Gb
    DVD-9:  8.5 Gb
    DVD-10: 9.4 Gb

    We recommend that you leave about a 6% safety margin on your discs. e.g. for a DVD-5 (or DVD-R) with 4.7 Gb, use no more than 4.46 Gb for your data.

  • Can you author my DVD for me?

    Yes, we offer full service DVD authoring.  Go to DVD authoring for more information.

  • I’m having you author my DVD.  What materials do you need?

    We will need you to provide MPEG-2 video files, any text needed for your menus and a layered Photoshop image for your menu design.