I was bored, so I wrote this long post comparing BD and HD-DVD. Hopefully it will help to dispell some myths and save us all a little time. I admit this is OT, but hey, this whole thread is OT.
Technical Specifications:
DVD:
Capacity: 4.7GB(single layer) 9.4GB (dual layer)
Laser wavelength: 650 nm
Numerical Aperture: 0.60
Protection Layer: 0.6 mm
Data Transfer Rate: 36 Mbps (1x)
Video Compression: MPEG2
Blu-Ray(BD):
Capacity: 27GB(single layer) 54GB (dual layer)
Laser wavelength: 405 nm
Numerical Aperture: 0.85
Protection Layer: 0.1 mm (and 0.6 mm ??)
Data Transfer Rate: 36 Mbps (1x)
Video Compression: MPEG2
HD-DVD:
Capacity: 20GB(single layer) 32GB (dual layer)
Laser wavelength: 405 nm
Numerical Aperture: 0.65
Protection Layer: 0.6 mm
Data Transfer Rate: 36 Mbps (1x)
Video Compression: MPEG2, H.264
Comments:
Laser Wavelength - BD and HD-DVD use the same wavelength, 405 nm. I know in my previous post I said that Sony was developing a 408 nm wavelength laser. Well, I checked the pamphlet again, and it says 408nm, and it says Blu-Ray. (I guess 405 nm and 408 nm aren`t very different. Most materials do not have wildly different refraction indices for slightly different wavelengths. Also, since BD has a protection layer that is 6 times thinner than HD-DVD, it is roughly 6 times less sensitive to the refraction of the protection layer.)
Protection Layer - This simply means the amount of material the laser beam has to pass through to reach the reflective layer (where the data is). I guess you could call it the cover layer instead, but it`s not my choice of terminology. This is not to be confused with the protection coating, which has to do with preventing scratches and the like.
A Little Physics
Quick and painless, I promise.
The three main characteristics of optical media are: wavelength, numerical aperture, and protection layer thickness. BD and HD-DVD have the same wavelength, so we can ignore that.
Disk Capacity is proportional to: (Numerical Aperture)^2/(Wavelength)^2
This is the physical limit - obviously, we need to consider ECC, file system overhead, etc... BD should theoretically allow 71% more data than HD-DVD, but that is clearly not the case. This may reflect a more conservative design.
Disk Flatness Tolerance is proportional to: (Wavelength)/(Protection Layer Thickness*(Numerical Aperture)^3)
A quick calculation shows that BD is about 160% more tolerant to disk flatness imperfections than HD-DVD.
Protection Layer Thickness Tolerance is proportional to: (Wavelength)/(Protection Layer Thickness*(Numerical Aperture)^4)
A quick calculation shows that BD is about 80% more tolerant to protection layer thickness imperfections
Similarities between HD-DVD and DVD
The most obvious and important similarity is the protection layer thickness. Both DVD and HD-DVD have protection layers of 0.6 mm, placing the data layer at approximately the center of the disk - CD/DVD/BR/HD-DVD all have a disk thickness of about 1.2 mm.
This similarity is the basis of the claim that HD-DVD and DVD have similar manufacturing processes. After the masters are created, single-layer DVDs are made by making two substrates (each 0.6 mm), coating a reflective layer on one of the substrates, and gluing them together, with the reflective layer sandwiched in between. HD-DVD can use almost the same process - but everything will be harder, due to the smaller pits and lower tolerances. (Creating the masters is quite different, of course)
BD Manufacturing
BD has a 0.1 mm protection layer. Thus it has a 1.1 mm substrate, and requires only one substrate per disk. The reflective layer and the 0.1 mm protection layer are then added to the substrate. This makes fabricating BD actually easier than HD-DVD - since only one substrate is needed, they don`t need to worry about birefringence. Not to mention they only need half the injection molding capacity.
Because the laser does not pass through the 1.1 mm substrate layer, it can be made of virtually any material that can provide rigid mechanical support for the reflective layer. Hence, it is entirely possible to make BR disks from mostly paper. Thus, the BR substrate layer can be cheaper than HD-DVD or DVD. As for right now, they just use a cheaper plastic. However, these savings amount to at most a few cents, since plastic very, very cheap.
Making BD disks from paper:
http://www.extremetech.com/article2/0,1558,1573314,00.asp
The thin protective layer and the high density make the BR more vulnerable to scratches and other surface damage. Thus, a hard protective coating is necessary, or a caddy. There are BR formats for both caddy and bare-disks. The bare disks will almost certainly have protective coatings. The protective coatings are spin-coated, and amount to, at most, a few cents. Coatings currently used can prevent scratchs from test needles with 200 mN force.
As mentioned before, BR disks have higher tolerance margins than HD-DVD disks, which should also make manufacturing the disks easier.
(There has been some talk of a 0.6 mm protection layer format, which would share the same production methods described for HD-DVD and DVD. However, this thicker protection layer would largely negate all the advantages of BD, so I find this confusing. If someone knows more about this, please enlighten me.)
HD-DVD and BR mastering
Because both have data densities much higher than DVD, they cannot use current DVD mastering techniques. The most straightforward method is e-beam lithography, but more ambitious (cheaper?) methods are deep-UV with liquid immersion (being developed for the semiconductor industry), and blue laser with inorganic resist (haven`t read up on this, my guess is the inorganic photoresist creates sharper masks). The latter method, also called phase transisiton mastering (PTM), was developed in house by Sony specifically for BR and is cheaper than DVD mastering.
However, I don`t see any good reason why PTM can`t also be used by HD-DVD, so I think the mastering costs should be roughly equal. (Unless licensing the IP from Sony adds a noticeable cost)
HD-DVD and BR players
HD-DVD and BR both use 405 nm, and DVD is 650 nm. Thus, they are both not compatable with DVD - both must have seperate lasers for DVD playback. BR has a numerical aperture of 0.85, HD-DVD is 0.65, and DVD is 0.60. Thus, they cannot have the same optical system. Maybe clever engineering can allow most elements of the optical system to be reused, but the fundamental fact remains that they have different optical specifications, and require different optical systems.
BD, because of the much thinner protective layer, does not need to worry as much about beam-splitting or disk tilt, simplifying player design.
As mentioned before, BR disks have higher tolerance margins than HD-DVD disks, which should make player design easier. (Now obviously, you can`t have it both ways - but I`m sure the BD consortum will distribute the higher tolerance between disk and player manufacturing specs in a way that minimizes total cost - they would have to be stupid not to)
Summary
HD-DVD is primary technical merit is some compatiability with DVD disk manufacturing. This should allow HD-DVD disks to be produced at prices similar to DVD disks relatively quickly, since many economies of scale have already been acheived by the DVD market.
BR is more technically ambitious, using a higher numerical aperture and thinner protective layer. This provides several advantages in both player design and disk manufacturing. The downside is that BR shares less in common with DVD manufacturing, although many of the same techniques, machines and materials can be reused. BD disk mass production has the potential to be cheaper than DVD disk production.
Second Opinion:
http://www.technologyreview.com/articles/04/07/wo_brown072204.asp