How to make a PVC cards ?

The majority of cards are manufactured by layering thin plastic sheets, one on top of the next. Between 3 and 7 layers are typically followed using a combination of heat and adherent to form a final sheet. Then the sheet is cut into finished cards at the manufacturing facility. In this production technique, it is not uncommon to find bad sheets in which two of the layers did not adhere correctly.

In such a case, the cards from this sheet will tend to split and peel. If you notice cards splitting into layers, talk to your card provider and have the remainder of your card stock checked or replaced. Often it will only impact a single sheet of cards but at times it could impact an entire lot.

Even though not as common–especially among the cards used as campus ID cards– some cards are manufactured via a technique known as injection molding. In this particular , the plastic material is forced into a mold to form the card. This is the same process used to make many of the items that are produced from plastic, everything from toy soldiers to automobile parts.

How it is formed?

Most ID card base material used to make polyvinyl chloride, or PVC. PVC is not new, in fact, the material is first created in the 19th century a laboratory. Commercial production began in the United States in the 1920s, and since then, PVC has grown into one of the world’s second most widely used plastic, everything from children’s toys to construction equipment, and discovery of identity cards.

PVC is created using salt and oil. For the chemists among us, the current running through decomposition when salt brine, chlorine and other by-products are formed. Oil or gas can be refined to produce ethylene, which, when combined with chlorine may eventually produce polyvinyl chloride. PVC contains chlorine 57% (by weight), it is a white powder in its initial state.

In pure form, PVC is rigid and holds ink or dye is good, but it has low elasticity and tend to break down. For these reasons, the PVC is usually mixed with other substances to form a plastic that can be used in carrying our ourwallets and purses.
In some cases, polyvinyl chloride mixed with other ingredients to make it more flexible and elastic or with other polyesthers make it more printable, uniform, and durable. A report produced by the International Card Manufacturers Association pointed out that the unique combination of 10 and 15 most cards mixture between components.

Other Card Materials

In recent years, the environmental negatives involved with the decomposition of PVC led many to seek alternatives. One of these alternatives that has been widely utilized in the card manufacturing arena is ABS. ABS can be combined with a PVC base in a layered production process or it can be used as the base polymer in injection molded cards. Due largely to the problems encountered laminating and printing on ABS cards using dye sublimation card printers, it has not been widely used in instant issuance environments such as college and university campuses. More often, ABS cards are used in mass manufactured cards (e.g. transit cards) that are not personalized at issuance.

Need to Know

The choice of card materials can seem daunting but there are a couple of rules to keep in mind to make it easier.
Establish which characteristics are most important to you–the card’s life expectancy, its endurance, or its worth? Have you had excessive levels of card mistakes in the past? Or has this not seemed a problem? Some mistakes is expected but more than 1 or 2% should raise warning flags.

Negotiate the type of plastic in dept with your system supplier or card provider. Find out the types of plastic they recommend, then research the manufacturers projected life span for the card. Make sure the answers are suitable to your campus needs. Ask the plastic provider for campus references and talk to that person about their experience with the stock. Remember, some breakdown should be expected, due to differing levels of card use and abuse.