A data storage device includes a substrate layer, made of a moldable non-photopolymer plastic substrate and having a servo layer, adjoined to a stacked film structure that is constructed of multiple functional films, having data layers, with spacer film(s) disposed between each of the functional films. Methods of manufacturing the data storage device include using a roll-to-roll system to adhere thin spacer film extrusions between the multiple functional film extrusions so as to construct the stacked film structure. An additional method uses an application of functional film coating to thin spacer films and a roll-to-roll system.