Optical Disc Label Printing Options

Action Duplication is now the only DVD and CD replicator capable of decorating optical discs with Offset, On-Disc Digital Printing, Silk Screen, 4-Color Direct Imprint or Black Direct Imprint. Images of samples and downloadable templates for each process can be found here.

Our new equipment allows us to print 4-Color Process images on optical discs with the same high resolution quality expected on offset printed paper.

Offset is best for extremely high quality 4-color process printing which closely matches printed packaging. Our new offset printer can print 85,000 discs per day. The resolution is a breathtaking 175 lines per inch. The press prints in CMYK plus 2 additional colors for adding a Pantone color and the white flood.

The print quality of our new press sets the standard for optical disc decoration. Offset is now the preferred process for printing the labels on new theatrical DVD releases. Because this state of the art press is quick to set up and uses economical consumables, we will be able pass on cost savings to our clients.

Action Duplication is one of the few companies in the world employing On-Disc Digital Printing. This new technology, developed by Auto-Tec AG, Switzerland, allows photo-quality images 600 dpi) to be printed on CDs and DVDs. The quality of the 4-Color process digital image offers higher resolution than the industry standard silk-screen printing process.

Additionally, the Digital Print Transfer process uniquely allows for the individual customization of the discs with variable data such as names, addresses, and serial numbers. The ability to personalize optical discs creates many new uses for the medium. Examples are personalized Direct Mail CDs, Business Card CDs, CD Concert Tickets, the serialization of secure content, and Limited Edition Collectible DVDs. The equipment can print 25,000 discs a day.

On-Disc Digital printing works by using a dry toner process to digitally print the images onto a film substrate and then coats the toner with a heat reactive adhesive. The film is placed in contact with disc and the adhesive is activated with heat. Under pressure, the activated adhesive pulls the toner off of the film and permanently bonds the toner to the disc. The finished disc normally has a vibrant high-gloss luster and can also be created with a matte finish. The print can accurately match accompanying 4-color process packaging The high resolution printing stands out when compared to conventionally printed product Action Duplication includes this process at no additional charge on most DVD replication projects. For CD projects there is a small upcharge.

Silk Screen printing is the most common and for larger quantities, the least expensive, process for disc decoration. The printing is done in 1 to 6 colors on a high speed press at up to 4000 units per hour. The inks can be printed on a white flood background, or directly onto the silver media. Dramatic effects can be created by designing the art so the silver shows through the art work in selected areas. When solid PMS colors are used at their full intensity, the richness and depth of silk screen ink produces stunning designs.

We prepare for silk screen printing by separating your art files into the component colors and creating a film for each color. These films are then used to burn screens which are fitted onto the press. We use 85 to 120 line screens. Silk screen inks can successfully reproduce 4 color process images. The inks are opaque and the CMYK colors are layered on the disc to be optically mixed by the viewer.

For short run 4-Color printing, primarily onto CD-R's, Action Duplication uses an industrial Rimage Process Color Thermal Transfer Printer. The quality of the print is very high and compares favorably with On-Disc Digital Printing. It also has a high gloss finish. There are no setup charges when using Direct Imprint. While it is a slower printer than the ones explained above, there is minimal setup and it can be used to produce several hundred high quality 4-Color printed discs overnight.


For short run 1-Color printing, we use a Rimage Thermal Transfer process. This method of printing is designed for labeling discs with text or line art graphics only. It is an efficient and inexpensive process for projects with very quick turn times.