The document outlines the technical and business considerations for mastering operations in media production, detailing processes from pre-mastering to post-production. It emphasizes the importance of quality control, equipment requirements, operational efficiency, and customer service within the industry. The document also highlights the need for ongoing feedback and process optimization to correlate mastering techniques with customer expectations.

1. www.stampertech.com
www.gomastering.com
www.facebook.com/stampertech

2.  The magic of mastering?
 Startup Considerations
 Need for Feedback (closed loop systems)
 Equipment
 Process
 People
 Process optimization
 Mastering is a science
 What’s next

3. Not if you know the tricks…
But it doesn’t mean that it’s easy.

4. Pre-Mastering
Stamper
Replication
laser
Molding
Acousto Opto
modulator 1,000’s
Glass Recording Plastic disc
(film exposure)
Mastering
Developing
Galvanics CD/DVD Player
(nickel plate)
Separation

5.  Business Plan and Model
 Types and quality of equipment
 Quality and experience of staff
 Core technical competency
 Unit Mfg Cost
 Media handling
 Utilities/Facilities
 Health, Safety, and Environmental
 Administrative
 Operations

6.  Revenues
 Target market
 Size of market
 Capacity based on yields and efficiencies
 Pricing strategy
 Costs
 Leaseholds and equipment capitals
 Staffing
 Consumables, Maintenance, Utilities, Facilities
 Rent and insurance
 Sales and marketing
 Yields and efficiencies
 Licensing
 Administrative and IT infrastructure

7.  Pre-Mastering
 Media, logical, and content testing; Network data transfers of DDP files (security and content
integrity)
 Mastering
 Glass cleaner, photoresist coater, laser beam recorder, developer, metallizer, inspection systems, PR
measurement/scanner, diffraction order measurement, optical densitometer.
 Galvanics
 Cleaning/passivation, plating cells, thickness measurement, protective coating.
 Utilities
 RO water, DI water, compressed air, chilled water, backup UPS, waste water treatment, exhaust.
 Post Production
 Stamper Testers, Inspection systems, microscopes, AFM, optical comparators, bit to bit verification,
digital and dynamic testing.

8.  Customer Service
 Operations President Front Office
Support
Technical Support
Facilities
 Customer Sales &
Support
Engineering Production
Service Marketing
IT Support
 Administrative Technician
0.6 per shift
Premastering Op)
1 per shift
Legal
Mastering Op
 Management 1 per shift
Galvanics Op
1 per shift
QA Op
 Sales and Marketing
1 per shift
 IT Support
 Legal Support

9.  Equipment capability and stability studies
 Process Development
 Training based on detailed operating procedures
 Operator Training
 Technical Training
 Documentation
 Users manuals
 Schematics
 Components Test Results
 Process procedures
 Spare parts and maintenance schedule

10.  Glass substrates (Cost/# of cycles)
 Laser (Cost/# of parts)
 Consumables
 Nickel pellets, acids, solvents, photoresists, alkalines, nickel targets, galvanics filters.
 Facilities
 Power, waste treatment, DI water production
 Cleanroom supplies
 Gloves, tacky mats, protective personal equipment, cleanroom notebooks and papers,
glass cases, face masks, cleaning solvents.
 Stamper Cases (Selected for best shipping ruggedness)

11.  Content rights
 Music
 Software
 Video
 Media quality
 CD’s, DVD’s, DLT’s, 8mm, Network.
 Format compliance
 DDP compatible, DVD spec, Philips Book specs.

12.  RO Water
 DI Water (resistivity, total organic content)
 Compressed Air (moisture and oil free)
 Electricity (total loads, transformers, UPS)
 Chilled Water (regulated temperature)
 Temp and Humidity Control
 Exhaust and flow control for balance
 Waste Water Treatment (complies to local reg)
 Plant monitoring system

13.  Osha compliance
 MSDS and rights to know
 Chemical labeling
 Harzardous communication
 Fire safety (evacuation plan)
 Environmental wastes
 Sewage permit
 Emissions permit
 Chemical handling/storage
 Ventilation

14.  Customer Service
 Credit Checks
 Accounts Payable
 Accounts Receivable
 Payroll/Benefits
 Human Resources
 Information Technology
 Sales and Marketing

15.  Scheduling
 Inventory
 Reporting
 Yields
 Failure Paretos
 Efficiency
 Product Tracking
 Quality Control (Statistical)

23.  Receive PO or Storefront Order
 Send confirm order to customer
 Create a workorder for each job with live 24/7 online status for customer
to monitor
 Receive physical media or FTP upload
 Check PO against Master
 Calculate due date based on turn time
 Automated production scheduling

24.  Verify WO against Source for ID info
 Verify content ownership
 Load source image into Image Server
 Check for virus
 Check for content compliance
 Check for logical structure integrity
 Enter playtime and any CDText into WO
 Create workorder sheet and send job to Mastering

25.  Program ID band into Laser Recorder
 Expose data onto photoresist glass
 Develop glass master with inline laser monitor
 Check exposure of each part with diffraction order offline to verify inline
developer
 Metallize glass master
 Inspect for defects
 Check HubID band on glass against work order
 Update online workorder status

26.  Program amp hours to make correct thickness for each
customer and make father from the glass
 Make mother and stamper if necessary
 Measure thickness of each part
 Inspect for defects
 Put protective coating on part

27.  Verify part needs to be finished
 Verify HubID band information
 Back sand each part
 Verify punch size on work order
 Punch part with matching punch size
 Inspect for defects and for burrs
 Update workorder online status

28.  Separate parts for CD’s and DVD’s
 Test using proper players
 Verify test results against specs
 Compare program time on work order against test results to
confirm correct content
 Inspect stamper for defects
 Update workorder online status

29.  Verify ID band on stamper against customer PO
 Verify program time on test result to source test result to
confirm correct source
 Verify punch size match work order
 Make label and put stamper in case

30.  Ship workorder in system and send paper work to A/R to
invoice
 Prepare packing slip for each customer
 Coordinate shipping carriers
 Send shipping information to customers

34. Metallized
Mastering System Glass with
Glass
Content
X + H(X) Y Z
Process Control System
H(Y)
X + H(X) Y Z
X + H(X) Y XZ + H(X) Y Z
X + H(X) Y Z
H(Y) H(Y) H(Y) H(Y)

35. Dev Flow
Dev Time
Laser Power
Laser Focus
Num Aperture
DI Temp
PR Sensitivity
PR Thickness
ce
lean
ur f a
ss C
s sS
Gla
Gla

36. Dev Flow
Laser Power Dev Time
DI Temp Num Aperture Laser Focus
Glass Clean Glass Surface PR Thickness PR Sensitivity

37.  Process Feedback
 Glass cleaning, photoresist coating, laser recording, developing,
metallizing, quality control, yield.
 Equipment Feedback
 Glass cleaner, photoresist coater, LBR, developer, metallizer, cycle time,
equipment efficiency.
 Human Resources Feedback
 Training, human error tracking, production efficiency.

38.  Glass Inspection
 PR profile and surface defects
 Laser profile and Intensity
 Diffraction Measurement
 AFM
 Dynamic Testing
 Logical Testing

40.  Glass Cleaner
 Chemical concentration, chemical level detectors, alarms.
 Photoresist Coater
 Chemical concentration, DI temperature, air temperature, humidity, airflow,
dispensing volume, rotational speed.
 Laser Beam Recorder
 Translational error, rotational error, focus error, beam direction error, effective
laser energy, laser mode, laser temp, beam shape.
 Developer
 Chemical concentration, DI temperature, air temperature, humidity, airflow,
dispensing volume, rotational speed, diffraction order.

41.  Glass preparation
 Surface defects, surface tension, residual grating, film.
 Photoresist coating
 Solvent cleaning, adhesion promotion, photoresist application, baking profile.
 Laser beam recording
 Laser power stability, laser quality, modulation transfer function (bandwidth),
focusing response, translation accuracy, rotational noise, vibration isolation,
optical path efficiency.
 Developing
 Development curve over time
 Metallizing
 Power ramp versus metallization density and quality

42.  More Cycle = Cheaper unit mfg cost
 Caustic solution to remove PR
 Acid to remove metals
 Neutralizer for surface tension
 Rinsing and drying
 Monitor quality with focus error and correlate to number of
usage

43.  Fine Cleaning
 Solvent Rinse
 Primer
 PhotoResist Coating
 Coating Curve
 Baking (40nm solvent reduction @ 130nm)

44.  White Light
 Scans entire glass surface quickly
 Thickness range 80nm – 400nm
 Resolution for defects
 Surface presentation for uniformity

45. PR Thickness Curve
600
PR Thick (nm)
500
400 20% PR Avg Thickness
300
200
100 10% PR Avg Thickness
0
200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
Rotation (RPM )
PR TTV Curve
9.0
8.0
7.0
TTV (nm)
6.0 20% PR TTV
5.0
4.0
3.0
2.0 10% PR TTV
1.0
0.0
200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
Rotation (RPM )

48. Modulator Curve Nonlinearity
0.8
Output Power%
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0 0.5 1 1.5 2 2.5
Input Voltage

50. Intensity
Laser control
Controller
Modulation Driver
AOM
EFM1
EFM/Atip EFM2 Modulation Driver
Encoder EOM
ATIP1
ATIP2
Source
(Media or Network)
Glass plate

52. 0th Order
1st Order
2nd Order
240 mm Glass Substrate

54. Developing

55.  Cantilever that deflect laser light to monitor surface
deflections
 73 deg max at 90 deg scan direction
 Nanometric resolution

56. Photodiodes
Laserbeam
Tip
Substrate

59.  Photoresist thickness as variable (X)
 Fix photoresist concentration
 Fix laser power
 Fix developing I1/I0
 Output parameters measurement (Y)
 Physical pits
 Dynamic test signals (I3/Itop, I11/Itop, Symmetry, PP)

61. AFM vs Interferom etry Com parison D/W vs I2/I1
190 0.45 y = 1.0602x + 0.0257
y = 1.0239x - 8.2325
Interferometer Thickness
180 R2 = 0.9961 R2 = 0.9932
0.4
170
I2/I1 Ratio
0.35
160
0.3
150
0.25
140
130 0.2
130 140 150 160 170 180 190 0.2 0.25 0.3 0.35 0.4
AFM Pit Depth D/W Ratio

64. AFM Depth/Width vs Dynamic Signals
1 0.1
Symmetry/PP
0.8 0.05
Contrast
PP
I11 0
0.6
-0.05
0.4 I3
-0.1
Sym m etry
0.2 -0.15
0 -0.2
0.2 0.25 0.3 0.35 0.4
AFM Depth/Width Ratio

65. I2/I1 vs Signals
0.9 0.1
0.8 0.05
PP
Symmetry/PP
0.7 0
I11
Contrast
0.6 Symmetry
-0.05
0.5
0.4 I3 -0.1
0.3 -0.15
0.2 -0.2
0.25 0.3 0.35 0.4 0.45
I2/I1

66.  Definitely a science not magic!
 Understand the science (theoretical models).
 Characterize the process.
 Develop empirical models.
 Statistically control the process as feedback loop using the models to
predict.
 Last but most important feedback is that from the voice of the customer
and correlate your mastering process to the customer’s process.

67.  Use existing well characterized processes for
application in new industries
 Diffractive Holography
 Authentication, Decorative
 Diffractive Optics
 Computer Generated Diffractive Optical Elements
 Microchannels, microfluidics

71. www.stampertech.com
www.gomastering.com
www.facebook.com/stampertech