Bank Card Production Technology: Complete Manufacturing Guide
Bank card production involves sophisticated manufacturing processes that transform raw plastic materials into secure payment instruments. Modern bank card manufacturing combines precision printing, lamination, and security feature integration to create durable, functional cards.
Primary Card Production Methods
The payment card industry employs three main production technologies, each suited to specific volume requirements and quality standards:
1. Sublimation Printing Technology
Sublimation printing excels for low-volume production runs of 300-400 cards or personalized products. This technology transfers dye from ribbon to plastic through heat application.
Sublimation Characteristics
- Color reproduction: Up to 16.7 million colors for photographic quality
- Resolution: 300 DPI for sharp images and text
- Ideal applications: Photo ID cards, membership cards, small batches
- Advantages: No setup costs, immediate production, variable data capability
2. Offset Printing for Medium Volumes
Offset printing serves medium production runs of 500-1000 units efficiently using specialized small-format printing machines.
Offset Printing Process
- Equipment: Compact machines (e.g., CF-785) designed for pre-cut cards
- Card specifications: Standard 54×86mm size, 0.2-1mm thickness
- Ink technology: UV-curable inks required for plastic surfaces
- Finishing: Protective UV lacquer coating essential for durability
Why UV-Curable Inks
Unlike paper, plastic has a non-absorbent surface requiring special treatment. Conventional offset inks would smear on plastic without UV curing. The UV lacquer seals the print and protects against wear.
3. Lamination Technology for High-Security Cards
Lamination represents the industry standard for chip cards and high-durability applications. This method creates multi-layer cards through heat and pressure bonding.
Lamination Production Process
- Sheet printing: Images printed on large plastic sheets (A3-A1 format)
- Layer assembly: Multiple material layers stacked ("sandwich" construction)
- Laminating: Heat and pressure fuse layers into solid cards
- Die-cutting: Precision cutting with optical mark alignment
Laminated Card Advantages
- Superior durability for extended card lifespan
- Integrated security features between layers
- Consistent thickness and quality
- Industry standard for payment cards
Security Feature Integration
Modern bank card production incorporates multiple security technologies to prevent counterfeiting:
Physical Security Elements
- Holographic overlays: Tamper-evident holographic images
- UV-reactive inks: Hidden features visible under ultraviolet light
- Embossing: Raised characters for visual and tactile verification
- Magnetic stripe: Encoded data for transaction processing
Electronic Security
- Microchips: EMV chips for secure transaction authentication
- Contactless antennas: NFC capability for tap payments
- Encrypted data: Secure storage of cardholder information
Material Options
Bank card production uses various materials depending on requirements:
Standard Materials
- PVC (Polyvinyl Chloride): Most common, cost-effective material
- PET-G: Enhanced durability and environmental resistance
- Polycarbonate: High-security applications, laser engraving compatible
Specialty Materials
- Metal cards: Premium stainless steel or titanium
- Wooden cards: Eco-friendly natural wood veneer
- Specialty cards: Phosphorescent and special effect materials
Production Method Selection Guide
| Method | Volume | Best For | Turnaround |
|---|---|---|---|
| Sublimation | 1-400 | Photo cards, prototypes | Same day |
| Offset | 500-5000 | Loyalty cards, promotions | 3-5 days |
| Lamination | 5000+ | Bank cards, high security | 5-10 days |
Quality Control in Card Production
Professional card manufacturing requires rigorous quality verification:
Testing Procedures
- Visual inspection: Color accuracy, print registration, defect detection
- Dimensional verification: ISO 7810 compliance (85.60 × 53.98mm)
- Durability testing: Bend, twist, and abrasion resistance
- Functional testing: Magnetic stripe and chip verification
Professional Card Manufacturing Services
At ASMO, we operate advanced production facilities covering all manufacturing methods. Our capabilities include sublimation, offset, and lamination technologies with integrated security features and full payment standards compliance.
Explore our specialized card solutions including biometric cards with fingerprint sensors and SIM cards for telecommunications.