Plastic Card Production Cycle: From Design to Delivery
The payment card production process encompasses a complete manufacturing cycle from initial design to final delivery. Understanding this comprehensive workflow helps organizations plan efficient card issuance programs for bank cards and other plastic card products.
Overview of Payment Card Production
Modern payment card production combines multiple specialized processes to create secure, durable, and visually appealing cards. Each stage requires precision equipment and quality control measures.
Production Stages
- Design and prepress: Artwork preparation and file processing
- Printing: Image transfer using selected technology
- Lamination: Layer bonding for durability
- Die-cutting: Precision card separation
- Personalization: Individual data application
- Quality control: Testing and verification
- Packaging and delivery: Secure distribution
Printing Technologies Comparison
Different printing methods suit various production requirements:
Offset Printing
- Best for: Large production runs (10,000+ cards)
- Advantages: Highest quality, cost-effective at volume
- Investment: Significant equipment investment required
- Resolution: Professional-grade color accuracy
Digital Inkjet Printing
- Best for: Small to medium volumes
- Advantages: Flexibility, quick corrections, variable data
- Quality: High resolution suitable for most applications
- Setup: Minimal preparation time
Sublimation Printing
- Best for: On-demand, single card production
- Resolution: 300 DPI standard
- Equipment: Desktop printers from accessible price points
- Limitation: Lower durability than laminated cards
Digital Printing Production Process
Digital production offers the best balance of quality and flexibility for most card programs:
Step-by-Step Process
- Image printing: Inkjet technology applies designs to plastic sheets
- Sandwich assembly: Multiple layers stacked with laminate overlay
- High-pressure lamination: Heat and pressure bond layers permanently
- Die-cutting: Cards separated with precision alignment
- Personalization: Individual cardholder data applied
- Final packaging: Cards prepared for secure distribution
Personalization Methods
Payment card production includes various personalization technologies for chip cards and magnetic stripe cards:
Visual Personalization
- Embossing: Raised characters for card numbers and names
- Tipping: Foil coloring of embossed characters (silver, gold)
- Photo printing: Cardholder photographs for ID verification
- Laser engraving: Permanent marking for high-security cards
Data Encoding
- Magnetic stripe: Track 1, 2, 3 data encoding
- Smart chip: EMV application and key loading
- Barcode: 1D and 2D barcode application
- Contactless: NFC antenna activation
Equipment Requirements by Volume
Production equipment varies based on card volume requirements:
Low Volume (1-1,000 cards)
- Desktop laminator
- Manual die-cutter
- Manual embosser
- Desktop card printer
Medium Volume (1,000-50,000 cards)
- Professional lamination press
- Automatic die-cutting machine
- Electric embosser with tipping
- Magnetic encoder
High Volume (50,000+ cards)
- Industrial offset press
- Automated lamination line
- CNC die-cutting systems
- Centralized personalization bureau
Material Selection
Payment card production uses certified materials meeting international standards:
Standard Card Materials
- PVC: Most common, cost-effective base material
- PET-G: Enhanced durability, environmentally preferred
- Polycarbonate: Highest security, laser engraving compatible
Premium Materials
- Metal cards: Stainless steel, titanium, brass
- Wooden cards: Sustainable wood veneer
- Specialty materials: Phosphorescent, translucent
Quality Control Checkpoints
Professional payment card production implements multiple quality verification stages:
Visual Inspection
- Color accuracy verification
- Print registration check
- Surface defect detection
- Dimensional measurement
Functional Testing
- Magnetic stripe read/write verification
- Chip communication testing
- Contactless range testing
- Embossing height measurement
Durability Standards
- ISO 7810 dimensional compliance
- Bend and twist resistance
- Temperature stability testing
- Abrasion resistance verification
Production Timeline
| Stage | Duration | Factors |
|---|---|---|
| Design approval | 1-3 days | Client feedback cycles |
| Printing | 1-2 days | Volume and method |
| Lamination | 1 day | Batch size |
| Die-cutting | 0.5-1 day | Automation level |
| Personalization | 1-3 days | Data complexity |
| Quality control | 0.5-1 day | Testing scope |
| Packaging | 0.5-1 day | Delivery requirements |
Professional Card Production Services
At ASMO, we offer complete payment card production services covering the entire manufacturing cycle. Our facilities handle all production stages with full payment standards compliance and secure processing environments.
Explore our specialized card solutions including biometric cards with integrated fingerprint sensors and e-wallet cards for digital payment integration.