The PLAYSTATION 3 Challenge

The biggest challenge during the development project was the decision to incorporate BD capabilities into PLAYSTATION 3. The Sony Group had helped to expand the DVD market by building a DVD player into PlayStation 2. When PlayStation 2 went on sale, the DVD market was still small. The availability of a game console that could be used to play popular games and watch DVDs made DVD technology familiar to people throughout the world.

Semiconductor laser technology also played a key role in the addition of CD/DVD playback capabilities to PlayStation 2. In PlayStation 2, we used a dual-wavelength semiconductor laser capable of emitting two types of lasers for CDs and DVDs. The result was a compact console that could playback both CDs and DVDs.

Without doubt, the inclusion of BD playback capabilities in PLAYSTATION 3 would help popularize BD technology. However, DVD products had already been on the market for some time when PlayStation 2 was developed, and we had a little more time to develop the semiconductor laser. The situation with PLAYSTATION 3 was totally different. When the product was under development, we only had a BD recorder capable of writing to BDs. The semiconductor laser in a BD recorder requires powerful output and is designed differently from the laser used in a player.

Furthermore, we had to develop a 3-wavelength semiconductor laser capable of playing three types of optical discs–CDs, DVDs, and BDs. And because people everywhere were eagerly awaiting the launch of PLAYSTATION 3, we also needed to prepare for mass-production on a far bigger scale than for existing BD recorders. Production of the new console would be measured in millions.

Panic, Pressure and Progress–Fighting against Time

In addition to developing a new semiconductor laser, we also had to design and develop equipment to mass-produce it. When I first heard about the development schedule, I thought it would be impossible. There are always problems with research and development relating to materials and devices. The conditions may be wrong, or a device fails to work properly. Progress is achieved through repeated efforts to overcome these setbacks. However, I began to think that Sony could probably succeed. I based that view on Sony's culture of accepting difficult challenges, on the wide-ranging talents of our engineers, and on the resources of technology and experience built by our predecessors.

To take the lead in the establishment of a new optical disc format, Sony needed to succeed in mass-producing PLAYSTATION 3. The successful introduction of PLAYSTATION 3 would result in the rapid establishment of a BD market and was therefore extremely important not only to Sony, but to the entire Blu-ray industry.

Normally technology is transferred from research facilities to the Business Groups that design new products, and from there to manufacturing facilities. To minimize the time required for development, I decided to skip the transfer of technology to the Business Groups by relocating our development operations to Sony Shiroishi. I moved to Shiroishi with an elite task force of seven of our younger research workers.

Semiconductor lasers are manufactured using the metal organic chemical vapor deposition (MOCVD) method. Substrates made from gallium nitride are placed in a special kiln, in which the vaporized substances are deposited in layers to create the semiconductors. Although MOCVD is the normal method used to fabricate semiconductor lasers, this was the first time that anyone had attempted to mass-produce semiconductor lasers using materials that emit blue-violet light. Initially we experienced one failure after another. We had to identify the many conditions required to form semiconductor crystals, including precise temperature control and heating times. Each failure resulted in a delay of several weeks before we could procure new parts. The development team was close to the limit of its ability to cope with the resulting panic and pressure. Staff from Sony Shiroishi helped us by carrying out the scientific tests needed to identify the causes of key phenomena and problems. They also struggled to set up to production and testing lines in readiness for the start of mass-production. We were all locked in a relentless struggle to develop the world's first semiconductor laser for use in a BD player. To make our task even more difficult, the laser had to be capable of emitting three different wavelengths.

Joys of Engineering

As the deadline loomed ever closer, the development team was supported by the efforts of Sony engineers. The Shiroishi facility was soon crowded with semiconductor fabrication experts from Sony Semiconductor Kyushu, and research personnel working in various fields at Sony research centers. As a result of this experience, I formed a profound awareness of the bonds that exist among Sony engineers.

Engineers who choose to continue their research at universities never enjoy the satisfaction of linking research results to business through the creation of products that bring pleasure to ordinary consumers. I have experienced that satisfaction because of my involvement in Sony's optical disc business. Once we were on track to the start of mass-production, we left Shiroishi and returned to Sony headquarters. I wanted to escape, in part because our development work had fallen behind schedule. However, when I got back to headquarters, I was greeted with applause, and everyone congratulated me for my hard work. It was in that moment that I realized how fortunate I was to have been involved in this project, and to work for Sony. The development of the BD semiconductor laser was a difficult project. I feel strongly that our success not only helped to improve our technology and knowledge, but also resulted in stronger human relationships. Perhaps it is this emotional dimension that motivates engineers to accept new challenges, regardless of the hard work required.