Chloe Zhang
Creating a plastic card, such as a business card, ID card, or membership card, can be done through various methods, depending on your budget and desired quality. Online services like MOO offer customizable templates and unique designs, with options for different paper types, finishes, and shipping speeds. For those seeking a more cost-effective approach, it is possible to create your own plastic cards at home. This typically involves purchasing blank card stock, which can be made of PVC or Teslin, and using a standard printer to add your desired design. To achieve a more professional look, a heavy-duty laminator can be used, and you may also consider adding features such as magnetic stripes or barcodes.
| Characteristics | Values |
|---|---|
| Material | PVC or Teslin |
| Size | 3.375” x 2.125” (CR-80) |
| Thickness | 30 mil |
| Finish | Gloss, satin, or matte |
| Color | White, blue, green, grey, orange, pink, red, tan, yellow, fluorescent yellow, fluorescent pink, fluorescent green, fluorescent orange, fluorescent blue, or fluorescent red |
| Magnetic stripe | Yes or No |
| Single-sided or double-sided | |
| Printer | ID card printer or standard printer |
| Printing method | Thermal ribbons or ink/toner |
| Ribbon color | Black, gold foil, red, blue, or colored |
| Cost | Varies depending on quantity, color, finish, and magnetic stripe |
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What You'll Learn
Buy pre-cut Teslin or card stock sheets
When creating a plastic card, you can buy pre-cut Teslin or card stock sheets. Teslin is a widely used synthetic ID card printing material. It is waterproof and works well with inkjet printers. Teslin sheets come in various grades, thicknesses, and sheet sizes, and can also be custom-ordered to your specifications. For example, Teslin sheets come in 8.5" by 11" full sheets, as well as smaller perforated sheets with pre-cut card punch-outs in sizes such as 4" x 6" or 2.125" x 3.375".
The type of Teslin you require depends on how you plan to print on it. If you have an inkjet printer, use Inkjet Teslin. If you have a laser printer, use Laser Teslin, which is designed to tolerate higher temperatures and minimise shrinkage during printing.
Teslin is a good option for printing IDs, maps, signs, restaurant menus, and more. It is secure and durable, with excellent opacity for printing colourful documents and bar codes. Teslin sheets are also lower in cost than competing technologies.
In addition to Teslin, card stock sheets are also available for purchase. Card stock is a type of paper that is thicker and more durable than regular paper, making it suitable for printing plastic cards.
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Use graphics editing software
To create a plastic card, you will need graphics editing software. You can use any software you are comfortable with, such as Adobe Photoshop, Illustrator, or even free online tools like Canva or Pixlr.
Step 1: Set Up Your Document
- Open your chosen graphics editing software.
- Set up a new document with the correct dimensions for your card. The standard size for a plastic card is 3.375" x 2.125" (CR-80), and the standard thickness is 30 mil.
Step 2: Design Your Card
- Use the tools and features within your software to design your card. You can add text, images, logos, and any other graphical elements.
- Consider the purpose of your card and include relevant information. For example, if it is a business card, include your name, company name, contact information, and logo.
- You can also choose from a variety of colours for your card, including white, light blue, medium blue, dark blue, hospital blue, cranberry, medium green, dark green, grey, orange, pink, red, tan, and yellow.
Step 3: Work with Layers
- Utilize layers in your software to organize your design elements. This will make it easier to edit and adjust your design as needed.
- Group similar elements together on separate layers. For example, you can have one layer for text, another for images, and another for background colours or patterns.
Step 4: Proofread and Edit
- Before finalizing your design, carefully proofread all the information on your card. Check for spelling and grammatical errors, and ensure that all the details are accurate.
- Use the editing tools to make any necessary adjustments to your design. This may include changing text sizes, colours, or the positioning of elements.
Step 5: Save and Export
- Once you are happy with your design, save your work.
- Export your design as a print-ready file. The preferred file format for printing is usually PDF, but you can also use high-quality image formats such as TIFF or PNG.
After designing your card, you can then proceed to print and laminate it to create your plastic card.
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Print your design
To print your plastic card design, you'll need to decide on the type of printer and materials you want to use. You can use an ID card printer, which uses thermal ribbons instead of ink or toner. These ribbons are available in black and colour, with some manufacturers offering gold foil or specific colours like red or blue. The cost of printing will depend on the type of ribbon you choose, with colour ribbons being more expensive than black ribbons. Alternatively, you can use a standard colour printer with printable card stock sheets that can be laminated.
When choosing a printer, consider the quality of the cards you want to produce. ID card printers will produce higher-quality cards, but they can be more expensive and may not be worth the investment if you're only printing a small number of cards. If you're printing a large quantity of cards, an ID card printer may be more cost-effective in the long run.
If you're using an ID card printer, you'll need to purchase blank plastic cards. These cards are similar in size and thickness to a credit card and come in a variety of colours and finishes, including gloss, satin, and matte. The cheapest option is usually white cards with a gloss finish, but you can also add a magnetic stripe for a small additional cost. If you want something more eye-catching, fluorescent cards are also available at a slightly higher price.
For those using a standard printer and laminator, you can purchase card stock sheets that are pre-cut to the desired size. You can also buy pouches to laminate the cards and add magnetic stripes if needed. This option may be more cost-effective if you're only printing a small number of cards, as the initial investment in the printer and laminator is lower.
When designing your card, consider the finish you want. Matte cards are shine-free and can be written on with a permanent marker, while gloss cards accentuate colour and give depth, making images more vibrant. Soft-touch cards have a luxury velvety coating, while high-gloss cards provide an even shinier finish. Choose the finish that best represents your brand or purpose and utilise design templates to create a professional-looking card.
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Laminate the card
Laminating a plastic card is a great way to increase its durability and longevity. Lamination is a clear layer of film that is applied to the top of a printed card for protection. It acts as a barrier to protect the images and text on your cards and makes them more resistant to wear and tear. This layer of protection acts as a nearly invisible forcefield, shielding your card from scuffs, scratches, and coffee spills.
There are two main ways to laminate a plastic card: outsourcing the process to a company or doing it yourself. If you choose to outsource, you can simply send your card design to a printing company, which will apply the laminate during the regular printing process. This is a quick and easy option that will save you time and stress. Many companies offer this service, and you may even be able to outsource the lamination to the same company that creates your cards.
If you prefer the DIY route, you will need to purchase a handful of materials and equipment, as well as set aside plenty of free time. You will need to buy your own laminator and laminate film. It is important to note that you cannot use just any laminator for plastic cards as they are thicker than paper and may not fit through the machine or seal properly. You will also need to be careful with the heat settings, as too much heat can damage the plastic or any sensitive components like chips.
There are several types of laminate films to choose from, each with its own benefits. Clear laminate provides a basic level of protection, while holographic laminate adds a layer of security by making your card more difficult to duplicate. You can also add custom features like watermarks and microscopic printing for even more security.
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Add a magnetic stripe
Adding a magnetic stripe to a plastic card allows it to store data. Magnetic stripes are made of ferromagnetic particles that are encoded with data based on polarity. An encoding device creates a pattern of positively and negatively charged particles, directed by a computer. This pattern of charged particles on the stripe can be read by a point-of-sale (POS) system, security system, or other types of swipeable devices.
When considering adding a magnetic stripe, you will need to select the proper type of magnetic stripe and encode it with data. There are two types of magnetic stripes: Low Coercivity (LoCo) and High Coercivity (HiCo). LoCo stripes are less expensive and are suitable for cards that do not contain highly secure data or get swiped frequently. They are often used for short-term applications such as gift cards. HiCo stripes offer greater durability and are better suited for cards that are swiped frequently and require high security. They are used for long-term applications and have a stronger magnetic field, making the encoded data more challenging to erase. The colour of the stripes also differs, with LoCo stripes being dark brown and HiCo stripes being black.
Once you have selected the appropriate magnetic stripe, you can proceed with encoding it. The encoding process involves using a system with a magnetic pull to magnetize the iron particles in different directions, creating a unique pattern for each card. The data is typically generated and exported from the system that will scan the cards, such as a POS system or membership/loyalty program. For example, a gift card will contain an account number used to look up the available monetary value. The data can be encoded sequentially or variably. Sequential numbering means each card will have a consecutive number, while variable data means each card will have a unique, random number sequence.
It is important to consider the encoding requirements to ensure compatibility with your software. These requirements may include the track (track 1, 2, or both), the number of characters, and the starting number. The data is usually exported in a CSV file format, and then the code is printed onto the magnetic stripe. It is also crucial to keep magnetic stripe cards away from demagnetizing agents such as certain phones and strong magnets.
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Frequently asked questions
You will need blank plastic cards, a printer, and a laminator. You can also buy pre-cut Teslin sheets and laminate pouches with magnetic stripes.
You can use a standard inkjet or colour laser printer.
BlankPlasticCards.com offers blank PVC cards in a variety of colours and finishes. You can also find card blanks from Walmart.
The standard size is similar to a credit card, measuring 3.375" x 2.125" (CR-80) and 30 mil thick.
The cost depends on the materials and finish you choose. Blank white cards with a gloss finish are approximately $0.05 each, while coloured cards range from $0.085 to $0.09 each. Fluorescent cards are priced higher at $0.125 to $0.14 each. The cost of printing each card will depend on the type of ribbon used, with black ribbon averaging $0.01-$0.02 per card side and colour ribbon averaging $0.28-$0.40 per card side.
