Sony is transitioning its Thalgau, Austria, manufacturing facility from disc production to optical microlenses. Dietmar Tanzer, president of Sony DADC, told ORF Salzburg that disc production is expected to fall to 10% of current volumes by 2028, leading to a plan to retrain 300 employees for new optical technologies. This shift follows a long-term reduction in physical media manufacturing across the company’s global operations.
Why is Sony reducing disc production?
The decline in physical disc manufacturing is a calculated move rather than a sudden change. According to Dietmar Tanzer, the Thalgau plant currently produces 600,000 discs every day. Half of that daily output is dedicated to PlayStation media.
However, Sony expects this volume to drop significantly. By 2028, the plant is projected to produce only 10% of its current disc volume. This decline mirrors a decades-long trend of winding down disc manufacturing. Sony has been moving away from physical media for years, and the reduction in PlayStation disc demand represents the final stage of this transition.
Sony’s manufacturing footprint has changed drastically over the last few decades. The company previously operated major facilities in the United States, including sites in New Jersey and Terre Haute, Indiana. The New Jersey plant closed in 2011. In 2022, Sony moved all manufacturing from Indiana to the Thalgau facility in Austria. The former Indiana site now focuses on different technologies, such as assembling components for automotive headlights.
Sony DADC has produced more than 26.4 billion discs to date. Of that total, 23 billion discs were manufactured at the Terre Haute, Indiana, facility between 1983 and 2022.
How much is Sony investing in microlenses?
To facilitate this transition, Sony has invested €30 million into the manufacturing of optical microlenses. ORF Salzburg reports that mass production of these lenses could begin as early as next year. The Thalgau plant serves as the headquarters for Sony’s disc-making division and appears to be its only remaining wholly owned manufacturing facility.
The transition is already underway. A video from December 2024 shows that the Thalgau plant was already working on microlens technology at that time. Interestingly, the production process for these lenses still utilizes disc-making technology. This allows Sony to repurpose existing infrastructure for a new market.
The company is also focusing on its workforce. Rather than laying off staff due to the drop in disc demand, Sony plans to retrain all 300 employees at the Thalgau plant to work with optical microlenses.
What are the potential uses for optical microlenses?
Microlenses are designed to bend light and are essential for various emerging technologies. While they have applications in consumer electronics, Sony appears to be targeting the automotive and wearable sectors.
The head of Sony’s micro optics division provided specific examples of these applications to ORF Salzburg. One potential use includes headsets, where precise light manipulation is required. In the automotive sector, the technology could be used for advanced signaling. For example, Sony is exploring the possibility of a car turn signal that is projected directly onto the asphalt.
Comparison of Manufacturing Focus
| Feature | Current (Disc Focus) | Future (Microlens Focus) |
|---|---|---|
| Primary Product | PlayStation & Media Discs | Optical Microlenses |
| Projected Volume | 600,000 discs per day | 10% of current disc volume by 2028 |
| Key Industries | Gaming & Entertainment | Automotive & Wearables |
Frequently Asked Questions
When will Sony stop making PlayStation discs?
Sony is not stopping immediately, but production volume at its Thalgau plant is expected to drop to 10% of current levels by 2028.
What are optical microlenses used for?
They are used to bend light in applications such as headsets and automotive signaling systems.
Where is Sony’s disc manufacturing located now?
The primary wholly owned facility is located in Thalgau, Austria.
What do you think about the shift from physical gaming media to optical components? Share your thoughts in the comments below or subscribe to our newsletter for more industry updates.
