BLULINE II BD50 - Singulus Technologies AG

BLULINE II BD50 

Enabling the Blu-ray Future 

Smart Solutions to Drive the Future.

02 

BLULINE II 

Replication of Dual Layer Blu-ray Disc 

Hollywood Studios want to take advantage 

of the enormous storage capacity of a BD50 

disc in order to deliver an unprecedented video 

and audio experience in Hi-def quality to the 

home consumer. For this reason, the availability 

of 50 GB Dual Layer Blu-ray Discs is a clear 

must for these formats. 

The Blu-ray format has definitively established 

itself as the new standard in the market. Highdefinition 

television, HDTV (HD Ready and Full HD), 

combined with the Blu-ray video format, is the 

new technology of the media sector. The market 

introduction of the 50 GB Dual Layer Blu-ray Disc 

was a show-stopper for the entertainment industry. 

The high storage capacity of the format enables 

optimum audio and video high-definition quality 

and also offers the ability to store bonus material 

such as additional trailers, interviews with directors 

and stars as well as BD-Java-based applications, 

enabling viewers to enjoy an interactive movie 

experience never before possible. 

SINGULUS' experience in the field of Blu-ray 

goes back to its early, exclusive partnership 

with the format developer Sony in 2005. 

SINGULUS has already installed several Blu-ray 

production lines at the biggest independent 

disc manufacturers. 

The SINGULUS Blu-ray Disc production system 

BLULINE II is designed for the economical 

production of Blu-ray Discs (BD ROM Single 

Layer and Dual Layer (BD ROM SL/DL), according 

to the specifications issued by the BDA. 

All production steps from molding, cooling, 

metallizing, wet-embossing, lacquering and UV 

curing to quality inspection are incorporated in 

the BLULINE II. Its functionality, speed and design 

will again set a new benchmark for the industry. 

The BLULINE II operates with one molding 

machine and comprises all the advanced features 

required for production of high end Dual Layer 

Blu-ray Discs. 

The most common technology for creating an 

additional information layer on a substrate surface 

is the the wet-embossing process. The benefit of 

the wet-embossing process is that it provides a 

very fine pit geometry and therefore generates a 

flawless electrical signal. 

This dual layer process requires an excellent 

uniformity of the space layer between the 

two information layers (approx. 25±1 micron). 

This space layer is created by our field proven 

spin coating process and uses resin heating 

and curing to achieve the required uniformity. 

Finally the BD50 disc requires a precise 75 micron 

cover layer. This process will be performed in the 

standard cover layer unit. 

Every single BLULINE in the field can be upgraded 

with the embossing technology to produce 50 GB 

Blu-ray Discs.

The following features characterize the 

BLULINE II concept: 

_ Dedicated to production of BD ROM SL/DL 

_ Cycle time BD SL < 4.0 s / BD DL < 6.0 s 

_ Highly integrated design 

_ All production steps included 

_ Thickness Measurement Device (TMD) 

for metallized layers with close loop 

control for the cathode 

_ Spectrometer for spacer-layer and 

cover-layer measuring with close loop 

control for spin process 

_ High productivity, high uptime 

_ Clear structured disc flow 

_ Automated handling of BD through all 

production steps 

_ Minimum space required

Sputter Station for Layer 0 

and Layer 1 Metallization 

For metallization of the molded Blu-ray Discs 

substrates with Layer 0 full-reflective material, 

one high sputter rate SINGULUS V module with 

the patented SMART Cathode ® is used. Silver 

Alloy is sputtered with a layer thickness of 

approx. 35 nm. For the second metallization 

of the wet-embossed disc with Layer 1 semireflective 

material, the same sputter station is 

used. A second sputter module is used for 

sputtering the label side of the disc with a 

moisture barrier. 

Dual Layer Cover-Layer Unit 

Lacquering for the cover layer takes place on 

a double track module for high throughput. 

Each track consists of one lacquer dispense 

system, two spin bowls and one IR lamp. One 

Xenon pulsed UV lamp is used altered for both 

tracks. By using the second spin bowl, a mask 

and the influence of heat from the IR lamp, 

a homogeneous thickness of cover layer is 

achieved. The combination of the UV station 

and an additional spin bowl creates a uniform 

shape and outer edge on the disc. 

05 

Concept 

Wet-Embossing Station 

The Layer 1 wet-embossing station is the key 

unit of the dual-layer application. This unit is built 

with a 4-position turntable and one embossing 

head. The embossing head is designed for the L1 

wet-embossing process with a Nickel stamper in 

the uncured pit-transfer resin. The Layer 0 disc 

is loaded onto a quartz glass for embossing and 

is centered with a center pin. The Layer 1 stamper 

is mounted onto to the top side of the embossing 

head and is supported by vacuum and a 

mechanical stamper holder.

06 

Main Components 

1 Injection Molding 

SINGULUS has qualified the MoldPro All-Electric 

molding machine for Blu-ray Disc production. 

Other qualified molding machines can be 

integrated on request. 

2 Cooling Conveyor 

A linear cooling conveyor transports the discs in 

a horizontal position through a separate conveyor 

belt to the downstream. This additional cooling 

of the substrates during transportation provides 

a uniform temperature distribution over the disc 

surface. 

3 Layer 0 Metallization 

A high-rate SINGULUS V sputter module with 

the patented SMART Cathode ® is used for 

the metallization of the molded Blu ray Disc 

substrates with Layer 0 full-reflective material. 

Silver Alloy is sputtered with a layer thickness 

of approx. 35 nm. 

4 Base Resin 

Lacquering takes place on a double track module 

for high throughput. Both tracks are connected to 

one lacquer dispense system, two spin bowls and 

one IR lamp. One Xenon pulsed UV lamp is used 

for each track. The combination of a spin bowl 

and the UV station creates a uniform shape and 

outer edge on the disc. 

5 Pit-Transfer-Resin 

This unit consists of one lacquer dispense systems 

and two spin bowls. The discs are transported 

by one handling system. Once the metallized and 

resign-coated disc reaches the first position, a 

highly accurate circular ring of lacquering agent is 

applied onto the disc with 2 µm pit-transfer-resin. 

6 Pre Curing 

A one-position turntable to pre-cure the center of 

the lacquered Blu-ray Discs is positioned just prior 

the wet-embossing station. 

7 Wet-Embossing Station 

The Layer 1 wet-embossing station is the key unit 

of the dual-layer application. This unit is built with 

a 4-position turntable and one embossing head. 

The embossing head is designed for the L1 

wet-embossing process with a Nickel stamper in 

the uncured pit-transfer resin. The Layer 0 disc is 

loaded onto a quartz glass for embossing and is 

centered with a center pin. The Layer 1 stamper 

is mounted onto to the top side of the embossing 

head and is supported by vacuum and a mechanical 

stamper holder. 

8 Layer 1 Metallization 

For the second metallization of the wet-embossed 

disc with Layer 1 semi-reflective material, the same 

sputter station is used as for Layer 0. Silver Alloy 

is sputtered with a thickness of approx. 30 nm. 

9 Cover Layer 

Lacquering for the cover layer takes place on a 

double track module for high throughput. After UV 

curing, the disc is positioned directly under a 

spectrometer to measure the cover layer thickness 

and uniformity. With these results, a closed loop 

cover layer control is generated to ensure constant 

thickness and uniformity. 

10 Hard Coating 

The hard coat is performed with a spin process, 

ensuring a very thin and uniform distribution of 

the hard coat material. Afterwards, the disc will 

be UV-cured and positioned on the conveyor. 

A flip-over handling arm brings the print side of 

the disc facing up. 

11 Barrier Layer 

A SINGULUS V module is used for sputtering the 

label side of the disc with a moisture barrier. SiN is 

sputtered with a layer thickness of approx. 10 nm. 

12 Final Inspection 

The unique layer thickness measuring system 

controls the layer thickness and layer uniformity 

of each metallized substrate automatically.

Main Features 

Format BD ROM 

Single Layer & Dual Layer 

Cycle time DL < 6.0 s 

SL < 4.0 s 

Space layer 25 µm 

Cover layer BD DL 75 µm 

Cover layer BD SL 100 µm 

Metallization 

Fully reflective layer Ag+ (approx. 35 nm) 

Semi reflective layer Ag+ (approx. 30 nm) 

Barrier layer SiN (approx. 10 nm) 

Available Options 

Adaption of BCA module 

Dimensions BLULINE II 

(with MoldPro Injection Molding Machine) 

Length 4500 mm 

Width 3700 mm 

Height 2080 mm 

7 

5 

4 9 

6 

3 

1 

8 

2 

11 

10 

12 

07

Headquarters 

SINGULUS TECHNOLOGIES AG 

Hanauer Landstrasse 103 

D - 63796 Kahl, Germany 

Tel. +49 6188 440-0 

Fax +49 6188 440-110 

sales@singulus.de 

www.singulus.de 

Affiliated Companies 

Germany 

HamaTech APE GmbH & Co. KG 

Tel. +49 7045 41-8 

info@hamatech-ape.com 

SINGULUS NANO DEPOSITION 

TECHNOLOGIES GMBH 

Tel. +49 6188 440-417 

info@singulus-ndt.de 

STANGL Semiconductor 

Equipment AG 

Tel. +49 8141 3600-0 

sales@stangl.de 

Netherlands 

SINGULUS MASTERING B.V. 

Tel. +31 407 5014-00 

info@singulus.nl 

Switzerland 

SINGULUS MOLDING AG 

Tel. +41 52 63262-00 

sales@singulus-molding.ch 

Sales Subsidiaries 

France 

SINGULUS TECHNOLOGIES France S.A.R.L. 

Tel. +33 3 893111-29 

e-mail: singulus@club-internet.fr 

Great Britain 

SINGULUS TECHNOLOGIES UK Ltd. 

Tel. +44 1793 7842-00 

e-mail: brian.walsh@singulusuk.com 

Italy 

SINGULUS TECHNOLOGIES Italia s.r.l. 

Tel. +39 0717 9303-12 

e-mail: singulus.italia@fastnet.it 

Latin America 

SINGULUS TECHNOLOGIES Ltda. Latin America 

Tel. +55 1136 4301-13 

e-mail: latinamerica@singulus.com.br 

Smart Solutions to Drive the Future. 

Singapore 

SINGULUS TECHNOLOGIES Asia Pacific 

Tel. +65 674 119-12 

e-mail: singulus@singnet.com.sg 

Spain 

SINGULUS TECHNOLOGIES Iberica 

Tel. +34 936 7500-25 

e-mail: singulus@singulusib.com 

Taiwan 

SINGULUS TECHNOLOGIES Taiwan Ltd. 

Tel. +886 2 274833-66 

e-mail: sales@singulus.com.tw 

United States and Canada 

SINGULUS TECHNOLOGIES Inc. 

Tel. +1 860 68380-00 

e-mail: sales@singulus.com 

02/2008-MetaCom Printed in Germany - Technical alterations reserved

BLULINE II BD50 - Singulus Technologies AG

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