Card Construction

Solid Core Cards (No Overlay)
Solid core cards are made from a single film printed on both sides. Manufactured without an overlay, the cards are usually protected with a varnish. They work well for customer, loyalty, and scratch-off cards, or any card with a short shelf life.
  • The cards require no collating or lamination
  • Cards are relatively low cost
  • Klöckner Pentaplast’s high manufacturing standards mean you get superior surfaces on both sides, which is essential for good print quality
Card Construction_Solid-Core(No-Overlay)
Solid Core Cards (With Overlay)
Solid core cards, made from a single film printed on both sides, can also be manufactured with an overlay. The overlay protects the surface artwork and increases the card’s shelf life.
  • This construction is suitable for all common card applications. An overlay is required for cards with security features and/or magnetic stripes. Magnetic stripe application is possible
  • Handling is relatively simple compared to split core construction. There is a short lamination time independent of core material (no core/core lamination)
  • Klöckner Pentaplast’s high manufacturing standards mean you get superior surfaces on both sides, which is essential for good print quality
Card Construction_Solid-Core(With-Overlay)
Split Core Cards
Split core cards are the best choice when you want both physical performance and high print quality. This construction method is suitable for any card application.
  • Klöckner Pentaplast quality is an advantage because our stringent process controls provide a wider process window throughout each step in the customer's manufacturing process. The films must have a well-balanced formulation to achieve sufficient bond strength together with minimum card flow
  • Only one side of the film is printed
  • Laminated cards have the best physical properties
  • This method is used when print press maximum core thickness for processing is 420 micron or less
Card Construction_Split-Core-Cards
Full-face Foil Cards
Foil cards are ideal when you need cards with high graphic appeal. They can be used for secure, non-secure, RFID, contact, contactless/RFID, loyalty, and gift cards.
  • Same lamination parameters as normal core films
  • Overlay films must be used with full-face foil cards
  • Traditional printing, laminating, and die-cutting methods can be used as in the processing of solid and split core cards
Card Construction_kp_foil_drawing
High VICAT Cards
High VICAT cards are required in environments with high temperatures and stress. Applications include GSM and pay TV cards.
  • VICAT is a measure of how much a card material will soften with increasing temperature. The higher the vicat, the higher the temperature necessary for lamination, and the higher the service temperature
  • Standard PVC films (homo-polymer) have a VICAT softening point of 76°C. Increasing or decreasing this value requires additives and increases materials costs
  • To achieve high VICAT values, we create special blends of ABS and PVC
Contactless Cards
Contactless cards are ideal for security access control and payment authorization.
  • They can be constructed in numerous ways. Typically, a pre-laminated inlay is covered by a highly opaque print film and overlay
  • They offer several advantages: non-intrusive authorization, quicker processing time at point of use, and superior security of stored data
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Klöckner Pentaplast Group
4 Kingdom Street
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