Materials for Plastic Card Manufacturing
Understanding the materials used in bank card production is essential for producing high-quality payment cards. Different materials offer unique properties that determine card durability, appearance, and functionality.
PVC - The Foundation of Card Manufacturing
Polyvinyl chloride (PVC) remains the most widely used material in plastic card production. This versatile thermoplastic offers an excellent balance of cost, durability, and print quality.
Key characteristics of PVC for card manufacturing:
- Standard thickness: 300-320 microns for base layers
- Excellent surface quality for offset and digital printing
- Good lamination adhesion properties
- Cost-effective for high-volume production
- Compatible with magnetic stripe and chip embedding
PVC cards are suitable for most payment card applications, loyalty programs, and access control systems.
Polycarbonate for Premium Durability
Polycarbonate represents the premium choice in bank card manufacturing. This engineering plastic offers exceptional performance characteristics:
- Temperature resistance: -100°C to +165°C operating range
- Superior impact resistance compared to PVC
- Ideal for laser personalization - changes color under laser exposure
- Multi-layer fusion at 180-220°C creates inseparable structure
- Cannot be delaminated after production
- Distinctive acoustic properties when dropped
Polycarbonate is the preferred material for ID cards, government documents, and premium banking cards requiring maximum security.
Laminate and Overlay Materials
Protective overlays are critical components in card production. These transparent PVC layers protect printed designs throughout card lifecycle.
Laminate specifications:
- Thickness: 60-80 microns
- Transparent PVC with adhesive coating
- Available with integrated magnetic strips (LoCo, HiCo)
- UV-resistant formulations for extended durability
- Holographic security options available
Printing Inks for Card Manufacturing
Specialized inks are required for plastic card manufacturing. Standard printing inks cannot bond properly with plastic substrates.
Offset Printing Inks
- UV-cured formulations designed for plastics
- Premium manufacturers: Apollo (UK), Siegwerk (Germany)
- Excellent color stability and adhesion
Digital Printing Inks
- Pigmented or water-based varieties
- Faster color changes between jobs
- Note: pigment inks may experience color shift during fusion
Hot Stamping Foils
Hot stamping adds metallic and holographic elements to payment cards:
- Gold and silver metallic options
- Holographic security foils
- Custom branded holograms available
- Applied at controlled temperature and pressure
Specialty Materials
Beyond standard materials, card manufacturing incorporates innovative options:
- Metal cores for premium cards
- Wood veneers for eco-conscious designs
- Recycled PVC for sustainable production
- Composite materials for enhanced durability
Related Services
Explore our material expertise across different card types:
- Smart chip cards with embedded electronics
- Biometric cards with fingerprint sensors
- Luminescent cards with special pigments
- Eco-friendly card solutions
Discover our full range of capabilities at ASMO360 or contact our Russian office at ASMO Russia.