They digitize the HDV footage to Final Cut Pro in the ProRes422 codec, at the end of their edit, the export to an UNCOMPRESSED QUICKTIME file.
That file is then taken to a a facility that allows them to take the individual uncompressed frames and they then laser-scan each frame out via a LASER to a film negative. Then it's processed and the video footage is magically now on actual film. They used to use a CRT (Cathode Ray Tube), but the LASER is much more precise.
They do a similar process for DI which is DIGITAL INTERMEDIATE, meaning they take film negative, scan it at 2K (meaning 2,000x2,000 pixels per frame), then the same process applies as above, but in most cases (and definitely in the case of CRANK 1 and 2), they color corrected the footage before outputting it to film negative.