CD, CD-ROM & DVD disc manufacturing and fulfilment in the UK, France and Italy

TECHNICAL SPECIFICATIONS & GUIDELINES: DVD MEDIA

March 2003

2001 - 2002 Disctronics Manufacturing (UK) Ltd

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Contents
Contents......................................................................................................................2 Introduction ................................................................................................................3 DVD Disc Formats ...................................................................................................3 DVD Application Formats .........................................................................................4 Pre-Mastering .............................................................................................................4 DVD-ROM ................................................................................................................4 DVD-Video ...............................................................................................................5 DVD-Audio ...............................................................................................................5 DVD: Acceptable Master Formats ............................................................................6 Digital Linear Tape (DLT).........................................................................................6 DVD-R Authoring and General Type........................................................................6

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Introduction
This document comprises a set of guidelines to help Disctronics' clients in preparing content for DVD replication. Disctronics offers a complete service for mastering, replicating and packaging DVD discs, complemented by our fulfilment and distribution services.

DVD Disc Formats

Disctronics can master and replicate the following DVD disc formats: DVD-5: single sided, single layer disc containing up to 4.7 GB DVD-9: single sided, dual layer disc containing up to 8.5 GB. DVD-10: double sided, single layer disc containing up to 9.4 GB

NOTE : DVD capacity is expressed in billions of bytes or 109 bytes. This contrasts with normal computer storage capacities whereby a GB is 1024 x 1024 x 1024 bytes. Therefore when data is being prepared using PC file structures the capacity of a DVD-5 disc should be written as 4.377 GB. Please refer to Table 1 for detail. For the purposes of this document, the Billions of Bytes nomenclature is used. Source data for these disc formats will need to be pre-mastered as described below and submitted for mastering on one of the appropriate master formats listed below. DVD-9 and DVD-10 discs will need the data to be submitted on two such media as two separate glass mastering operations are required.

Producing DVD-5 Discs

A DVD-5 disc is a single sided disc comprising one data layer with a capacity of 4.7 GB. It is the simplest DVD format to replicate and requires only one stamper, like a CD. The finished disc, like all DVDs, consists of two substrates bonded together. DVD-5 discs can be printed in the normal way.

Producing DVD-10 Discs

A DVD-10 disc is double sided disc, each side comprises a single layer. The capacity of a DVD10 disc is 9.4 GB. DVD-10 discs require two stampers, one for each substrate. The disc is accessed using one side at a time. As a DVD10 disc has data on both sides, printing is limited to a small central annular area on both sides of the disc.

Producing DVD-9 Discs

A DVD-9 disc is a single sided disc, comprising two layers, both read from one side with a capacity of 8.5 GB. Unlike a DVD-10 disc a DVD-9 disc does not need to be turned over to play the whole disc. The data layer closest to the read laser is called layer 0 and the layer further from the read laser (therefore closer to the label side) is called layer 1. The DVD9 layers can follow a Parallel Track Path or Opposite Track Path structure (see diagram below). The former is intended for DVD-ROM applications, while the latter is used for DVD-Video where a single movie occupies both layers. The OTP structure is designed to help smooth the transition from layer 0 to layer 1 during continuous video playback.
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Single layer disc Lead In Data Area

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Lead Out

Dual layer disc Parallel Track Path Lead In Lead In Data Area (Layer 1) Data Area (Layer 0) Lead Out Lead Out

Dual layer disc Opposite Track Path Lead Out Lead In Data Area (Layer 1) Data Area (Layer 0) Middle Area Middle Area

When a DVD-9 disc is inserted into a DVD drive, the data it contains represents a single volume of 8.5 GB. The data is split between the two layers but the file system information, which identifies the files and their position on the disc, is contained in layer 0, but references files in both layer 0 and layer 1. To replicate a DVD-9 requires two stampers which are created from two sets of data. The data must be correctly premastered or authored as a single volume and the layer change positioned correctly. For a DVD-Video disc, the two layers should contain approximately the same amount of data, with layer 1 being slightly smaller than layer 0. The ideal difference between the layers is 20 to 30 000 sectors or 40 to 60 PC Megabytes. For a DVD-ROM disc the only requirement is that each layer must contain a maximum of 4.25 GB of data. Therefore a DVD-9 requires two disc images, which will normally be contained on two DLTs together with the necessary DDP and control data (see below). The DDP must contain information indicating that the disc is a DVD-9 and which layer is contained on that DLT.

DVD Application Formats

Disctronics can master any of the following application formats in any of the above disc formats: DVD-Video: for movies and other videos with optional CSS (Content Scrambling System) and Macrovision APS (Analogue Protection System) copy protection. DVD-Audio: for high quality music albums with optional CPPM (Content Protection for Pre-recorded Media) copy protection. DVD-ROM: for games, multimedia applications and computer data.

Pre-Mastering
Disctronics can carry out pre-mastering prior to glass mastering or arrange for a third party to perform pre-mastering depending on the application format. Any such pre-mastering work will incur additional charges. Any pre-mastering work will required authorisation by the Client.

DVD-ROM
DVD-ROM pre-mastering involves formatting files using the UDF/ISO 9660 bridge file systems and transferring to DVD-R or DLT ready for mastering. DVD-ROM (and DVD-Video) discs not correctly formatted using the UDF bridge
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will have compatibility problems with the variety of PC operating systems in use worldwide. For DVD-5 or DVD-10 discs, the formatted data can be written to one (for DVD-5) or two (for DVD-10) DVD-R discs so that the Client can carry out full testing prior to mastering. Glass mastering can be carried out from an approved DVD-R master disc (or discs if for a DVD-10). This applies to both DVD-R for General Use and DVD-R for Authoring. For DVD-9 discs, formatted data must be written to two DLT tapes and cannot be tested before glass mastering.

Data for premastering should be supplied on suitable media together with a directory listing of all files. The accuracy of this information is particularly important if the data is to be mastered and replicated as a DVD-9 as such discs cannot be tested prior to replication.

DVD-Video
Disctronics can arrange for your source data (video, audio etc) to be premastered or authored to the DVD-Video format ready for glass mastering from suitable media. Please contact Disctronics for more information. Pre-mastering can include video and audio compression, creating menus and adding navigation. For DVD-5 or DVD-10 discs, the formatted data can be written to one or two DVD-R discs so that the Client can carry out full testing prior to mastering. Glass mastering can be carried out from an approved DVD-R master disc (or two such discs if for a DVD-10). If CSS and/or Macrovision copy protection are required the data must be written to DLT tape (see below). For DVD-9 discs, the formatted data must be written to two DLT tapes (for layer 0 and layer 1) and cannot be tested before glass mastering.

DVD-Audio
Disctronics can arrange for your audio data plus any images, video, text etc to be pre-mastered to the DVD-Audio format ready for glass mastering from DLT. Please contact Disctronics for more information. Pre-mastering can include audio encoding, creating menus and adding navigation. For DVD-5 or DVD-10 discs, the formatted data can be written to one or two DVD-R discs so that the Client can carry out full testing prior to mastering. Glass mastering can be carried out from an approved DVD-R master disc (or two such discs if for a DVD-10). If CPPM copy protection is required the data must be written to DLT tape (see below). For DVD-9 discs, the formatted data must be written to two DLT tapes (for layer 0 and layer 1) and cannot be tested before glass mastering.

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DVD: Acceptable Master Formats

DVD discs can be mastered from content recorded on any of the following medi a formats:

Digital Linear Tape (DLT)

DVD image data can be supplied on DLT tape (type III is recommended) using any of the following DLT drives to write the tape: DLT4000 DLT7000 DLT8000 DLT1 DDP ver 2.0 or 2.1 file with information on the type of disc, number of layers etc (see Disc Description Protocol specification). Control Data file which will be written to the lead-in area of the disc. Image Data file comprising the data in sectors. CMF ver 1.00, 1.10, 1.11 and 1.20 are also acceptable. (see Cutting Master Format specification)

The tape must be ANSI labelled and contain the following data:

NB Each layer of a DVD-9 and each side of a DVD-10 disc needs a separate DLT containing the data for that layer/side. It is also important to ensure that both tapes for a DVD-9 are written from the same pre-mastered data. Any change in one layer will require a new DLT for each layer. Please clearly identify each DLT tape, with the following information: Disc type: DVD-5, DVD-9 or DVD-10 Format: DVD-ROM, DVD-Video, DVD-Audio or combination Layer/side: For DVD-9, layer 0 or 1; for DVD-10, side A or side B. Path (for DVD-9): Parallel Track Path (PTP) or Opposite Track Path (OTP). Note that DVD-Video will usually be OTP and DVD-ROM will usually be PTP.

DVD-R Authoring and General Type

Either of these formats can be used as input media for glass mastering any DVD with the following exceptions. DVD-R General Type is sometimes called DVD-R General Format or General Purpose. Any DVD containing CSS digital copy protection can only be mastered from DLT. Discs using Macrovision APS do not cause a problem. DVD-9 dual layer discs cannot be mastered directly from DVD-R but only from DLT. It is not possible to master a DVD-9 from two DVD-Rs without re-authoring the media for DLT. DVD-10s, with no copy protection, will need two DVD-Rs, one for each side.

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DVD-Rs supplied as a master should be free of scratches/scuffs etc. since these may cause failure during the glass mastering process thus delaying the order schedule.

PLEASE NOTE:
Disctronics cannot change the Macrovision type without RE AUTHORING the media. It is NOT possible to take 2 DVD-5 or a DVD-10 media and make a DVD-9 disc without RE AUTHORING the media. It is NOT possible to take a DVD-9 media and make two DVD-5 or a DVD10 disc without RE AUTHORING the media. Please clearly identify each DVD-R, with the following information: Disc type: DVD-5 or DVD-10 Format: DVD-ROM, DVD-Video, DVD-Audio or combination Side: for DVD-10, side A or side B.

Special Notes for DVDR General Use :

DVD-R for General Use is a relatively new format. The systems using to create the discs and the systems used to Master from the discs are constantly developing. If DVD-R General is to be used as a Mastering Input Media, Disctronics strongly recommend that the media is created as: Single Session, UDF Bridge Format. If it is necessary to create a Multi Session or non UDF / ISO format product please contact Disctronics Customer Services. _____________________________________________________________

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Table 1 :
Format Sectors DVD-5 DVD-10 Side A DVD-10 Side B DVD-9 L0 DVD-9 L1 DVD-9 2 294 912 2 294 912 2 294 912 2 084 960 2 084 960 4 169 920 Bytes 4 699 979 776 4 699 979 776 4 699 979 776 4 269 998 080 4 269 998 080 8 539 996 160 Capacity PC Giga Bytes 4.377 4.377 4.377 3.977 3.977 7.953 3 2 Notes 1

It is advisable to utilise only 96% of available DVD capacity for user data. The 4% overhead is required for menu graphics, navigation information and a little safety cushion for manufacturing tolerances. The total number of user data sectors on any one layer should be divisible by 16. NOTES : 1) Customers formatting DVD-ROM discs should set the user data limit at less than the figures shown for DVD5. 2) A DVD-9 layer carries less information than a DVD-5 because the DVD-9 pit length is slightly longer than a DVD-5. This longer pit size is required to improve the signal strength of the semi reflective DVD-9 disc. 3) Customers formatting DVD-ROM discs should set the user data limit at less than the figures shown for DVD-9. The data size for layer 0 should always be greater than layer 1. The ideal difference is around 20 to 30 000 decimal sectors (40 to 60 PC Megabytes).

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