sale@zxcprint.com

Expert Custom
Plastic Card Printing
High-Quality Materials | Luxury Finishes | Fast Turnaround

Plastic Card Printing
CR80 (85.6 × 54 mm) & Custom Standard & Custom Card Sizes
PVC, PET & Eco Materials Magnetic Stripe, IC Chip, Barcode & NFC
5–10 business days Turnaround Time

Start your Plastic Card Printing project with a free quote. Click here to Inquire.

The Complete Guide to Plastic Card Printing

Looking for custom plastic card printing? ZXC Print manufactures PVC, PET, and eco-friendly plastic cards with full-color offset, silkscreen, and digital printing, from standard CR80 credit-card sized membership cards to custom-shaped contactless smart cards. We produce magnetic stripe cards, barcode cards, hotel key cards, gift cards, and access control cards with in-house Heidelberg offset, die-cutting, silkscreening, and encoding equipment. Runs from 500 to 500,000+ cards. Free quote and pre-production samples available.

What Is Plastic Card Printing?

Plastic card printing is the industrial process of manufacturing custom identification, payment, membership, and promotional cards from rigid or flexible plastic substrates. Unlike paper-based cards, plastic cards are durable, water-resistant, and capable of carrying functional elements such as magnetic stripes, embedded microchips, NFC antennas, and barcodes.

The production process begins with plastic sheeting (typically PVC or PET) that is printed using offset, silkscreen, or digital methods, then laminated for protection and durability. Printed sheets are cut to individual card blanks via precision die-cutting. Functional encoding (magnetic stripe, IC chip bonding, or barcode printing) is applied at the final stage.

ZXC Print has operated since 1998 and runs Heidelberg offset presses alongside dedicated card finishing equipment for magnetic stripe encoding, chip embedding, numbering, and barcoding. All card production (printing, lamination, die-cutting, encoding, and quality inspection) is completed in-house for consistent turnaround and quality control.

Related services: promotional printing.

Plastic Card Types & Applications

We produce a wide variety of plastic card types, each designed for specific use cases. Below is a breakdown of the most common card categories and their typical applications.

  • Membership & Loyalty Cards: Standard PVC cards issued by gyms, retail chains, clubs, and airlines. Typically printed with full-color branding, a member barcode or magnetic stripe, and a signature panel. CR80 (85.6 × 54 mm) is the standard size.
  • Magnetic Stripe Cards: Cards coated with a magnetic stripe (ISO 7811 track 1/2/3) storing encoded data. Used for hotel key cards, gift cards, student ID cards, and prepaid payment cards. Stripe is high-coercivity (HiCo) or low-coercivity (LoCo) depending on reader requirements.
  • Contactless IC Cards: Smart cards with embedded RFID/NFC antenna and chip for tap-to-read access. Common in hotel key cards, transit passes, building access control, and event wristbands. Compatible with ISO 14443 Type A/B standards.
  • Contact IC Cards (Chip Cards): Cards with an embedded microprocessor chip visible on the card face. Used for EMV payment cards, national ID, healthcare cards, and SIM cards. The chip contacts connect directly to a reader when inserted.
  • Hotel Key Cards: Typically magnetic stripe cards in standard CR80 size with property branding. Increasingly available as contactless IC cards (MIFARE Classic or DESFire) for enhanced security. Printed with hotel logo, room number, and check-out date.
  • Barcode Cards: Cards carrying a printed barcode (Code 128, Code 39, EAN, or PDF417). Used for product identification, warehouse inventory, library cards, and patient wristbands. Barcode is printed over the laminated surface during finishing.
  • Gold / High-end Cards: High-end plastic cards with metallic hot foil stamping, embossed numbering, gold or silver decorative borders, and high-end lamination. Popular for VIP membership tiers, high-end loyalty programs, and executive identification cards.
  • Gift Cards: Prepaid stored-value cards for retail and e-commerce. Available with magnetic stripe, barcode, or scratch-off PIN panel for online redemption. Custom shapes, branded artwork, and gift card holder packaging available.
  • Access Control Cards: Heavy-duty PVC cards with RFID or Proximity technology for door entry systems. Used in offices, gated communities, universities, and industrial facilities. Typically printed with company logo and user photo area.
  • Scratch Cards: Cards with a removable opaque silver foil panel concealing a PIN, code, or reward. Used for prepaid phone top-ups, instant-win promotions, and gift vouchers. Produced with a textured scratch-off coating over the concealed area.

Standard Sizes & Dimensions

Plastic cards follow established industry size standards. The ISO/IEC 7810 standard defines the ID-1 format (CR80), which is the most widely used plastic card size worldwide. Custom sizes and shapes are also available for branding differentiation.

Format Dimensions Thickness Range Common Use
CR80 (ID-1) 85.6 × 54 mm 0.30 – 0.84 mm Credit cards, ID cards, membership cards, gift cards, and hotel keys. The de facto global standard
CR79 83.9 × 51.0 mm 0.30 – 0.76 mm Pre-cut card blanks used in some ID card printers; slightly smaller than CR80
CR100 98.5 × 67.0 mm 0.30 – 0.84 mm Larger format for driver's licenses, student ID badges, and oversized access cards
Custom Shapes Any custom outline 0.30 – 0.84 mm Branded key tags, unique gift card shapes, promotional swag cards, luggage tags

Thickness note: Standard CR80 cards are 0.76 mm (30 mil). Smart cards with embedded IC chips typically require 0.84 mm (33 mil) due to the chip module thickness. Custom die charges apply for non-standard shapes.

Material Options

The substrate material determines the card's rigidity, durability, environmental footprint, and printing compatibility. Below is a comparison of the materials we offer for plastic card production.

Material Thickness Range Best For Characteristics
PVC Rigid 0.30 – 0.84 mm Standard membership cards, gift cards, ID cards, hotel keys Excellent print adhesion, flexible enough for embossing, rigid enough for daily use. Accepts magnetic stripe, IC chip, and barcode encoding. Most cost-effective option for high-volume runs.
PVC Flexible 0.30 – 0.50 mm Key tags, luggage tags, bendable promotional cards Softer and more pliable than rigid PVC. Good for cards that need to flex during use. Can be printed and laminated using the same processes as rigid PVC.
PET (Polyethylene Terephthalate) 0.30 – 0.76 mm Eco-conscious branding, long-life cards, chip cards Recyclable material with higher heat resistance and lower environmental impact than PVC. Less flexible than PVC. Accepts offset and digital printing with proper surface treatment. Compatible with most encoding options.
Eco-Composite / Biodegradable 0.50 – 0.76 mm Green branding, sustainable loyalty programs, eco-certified products Made from recycled or plant-based polymer blends (PLA/PHA). Compostable under industrial conditions. Print quality is comparable to PVC. Limited availability for custom shapes and very high volumes.
PET-G (Glycol-Modified PET) 0.30 – 0.76 mm Cards requiring high transparency, key tags Crystal-clear material with excellent clarity. Stronger and more chemical-resistant than standard PET. Often used for transparent or translucent ID cards and clear promotional cards.

Printing Technologies

Each plastic card printing method offers different trade-offs in color quality, cost per unit, setup time, and run length suitability. The choice depends on quantity, design complexity, and functional requirements.

Technology Color Capability Advantages Limitations Run Size
CMYK Offset Printing Full-color (CMYK + Pantone spot) Highest color accuracy and consistency across the entire run. Sharpest halftone reproduction for photographic images. Best per-unit cost at volume. Heidelberg offset presses deliver precise registration. Supports Pantone spot colors for brand-matching. Higher initial setup cost (plate making). Minimum run of approximately 1,000 cards for economic feasibility. Color adjustments require re-plating. 1,000 – 500,000+
Silkscreen Printing Spot colors only (opaque inks) Thick, vibrant ink laydown with excellent opacity on dark substrates. Pantone matching available. Low plate cost. Good for designs with large solid color areas or metallic ink effects. Not suitable for photographic images or fine halftones. Each color requires a separate screen and pass. Color registration is manual. Slower per-unit speed compared to offset. 500 – 50,000
Digital Printing Full-color (CMYK) Zero setup cost; prints directly from digital file. Variable data printing (each card can have unique text, barcode, or image). Fastest turnaround for small runs. Ideal for short-run membership card programs with personalized member data. Higher per-unit cost than offset at large volumes. Color gamut may be narrower than offset. Lower resistance to UV fading without lamination. Print speed limits throughput on very large orders. 500 – 10,000

Hybrid approach: For complex orders, ZXC Print combines methods: offset printing for the card face artwork and silkscreen for metallic or opaque spot colors, with digital variable data printing for personalized member information.

Encoding & Functionality Options

Plastic cards are often more than printed visuals. They carry data, security features, and electronic access functions. Below is an overview of the encoding and functionality options available.

Technology Data Capacity Standards Typical Read Range Applications
Magnetic Stripe 3 tracks, up to 226 alphanumeric characters ISO 7811 (track 1/2/3), HiCo (2750 Oe) or LoCo (300 Oe) Contact swipe only Hotel keys, gift cards, student ID, prepaid cards, parking passes
Contact IC Chip (Smart Card) 4 KB – 144 KB (EEPROM) ISO 7816 (contact interface), EMV Level 1 & 2 Contact (insert reader) EMV payment cards, healthcare ID, SIM cards, e-purse applications
Contactless IC (NFC / RFID) 144 bytes – 8 KB (MIFARE Classic); up to 80 KB (DESFire EV3) ISO 14443 Type A/B (13.56 MHz), ISO 15693 (vicinity), NFC Forum Up to 10 cm (ISO 14443) or up to 100 cm (ISO 15693) Hotel key cards, transit passes, access control, contactless payment, event badges
Barcode / QR Code Variable (Code 128: up to 48 chars; QR: up to 7,089 numeric) Code 128, Code 39, EAN-13, PDF417, QR Code, Data Matrix Scanner line of sight (contact or near-contact) Warehouse tracking, library cards, patient wristbands, membership scanning
Signature Panel N/A (physical writeable strip) White or ghosted-text adhesive panel applied to card surface Visual verification only Credit cards, ID cards, membership cards requiring signature verification

Encoding note: Magnetic stripe encoding and IC chip bonding are performed in-house on dedicated equipment. Barcode and QR codes are printed with high-contrast black on white after lamination for optimal scanner readability.

Decorative Finishes

Decorative finishes enhance the visual appeal, tactile feel, and perceived value of plastic cards. These are especially popular for high-end membership tiers, hotel key cards, and high-end gift cards.

Finish Application Cost Level Best Results On
Gloss Lamination Full-surface high-gloss protective overlay Standard All substrates; most common finish for membership and gift cards
Matte Lamination Full-surface non-reflective protective overlay Standard All substrates; preferred for signature panels and photo ID cards
Soft-Touch Lamination Velvet-like tactile coating on the card surface Moderate PVC and PET; most effective on smooth, untextured cards
Spot UV Varnish Selective high-gloss coating on logos, text, or decorative elements Moderate Matte-laminated cards for contrast between matte field and glossy spot
Hot Foil Stamping Gold, silver, rose gold, copper, or holographic metallic foil applied to specific areas High-end PVC rigid; uncoated card surface for best foil adhesion
Embossing / Debossing Raised or recessed text, logo, or pattern on the card surface High-end PVC rigid card stock (0.76 mm minimum); classic credit card embossed numbering
Numbering & Barcoding Sequential or custom numbers printed, embossed, or laser-engraved Moderate All substrates; includes magnetic stripe encoding alignment
Scratch-Off Panel Opaque silver or gold removable foil covering a specific area Moderate PVC rigid; typically applied over a pre-printed PIN, code, or reward text

Industry Applications

Plastic card printing serves a diverse range of industries. Below are the most common use cases we fulfill at ZXC Print.

Corporate & Enterprise: Employee ID badges, access control cards, visitor passes, business membership cards
Hospitality: Hotel key cards (magnetic stripe and contactless), VIP loyalty cards, guest feedback cards
Retail & E-Commerce: Gift cards, store credit cards, loyalty program cards, scratch-off promo cards
Banking & Finance: Debit and credit EMV chip cards, prepaid cards, payroll cards, corporate credit cards
Healthcare: Patient ID cards, insurance membership cards, prescription discount cards, medical record access cards
Education: Student ID cards, library cards, cafeteria payment cards, campus access cards
Transportation & Transit: Contactless transit fare cards, parking permits, toll pass cards, airline loyalty cards
Events & Entertainment: Event badges, conference passes, casino player cards, theme park season passes
Promotional & Marketing: Branded giveaways, promotional discount cards, referral reward cards, swipe-for-discount programs
Government & Security: National ID cards, driver's licenses, social security cards, secure access badges

Frequently Asked Questions

What is the standard plastic card size?
The global standard for plastic cards is CR80 (85.6 × 54 mm), defined by ISO/IEC 7810 ID-1. This is the size of a standard credit card or driver's license. We also produce CR79 (83.9 × 51.0 mm), CR100 (98.5 × 67.0 mm), and fully custom shapes. Standard card thickness is 0.76 mm (30 mil), with chip-embedded cards typically requiring 0.84 mm (33 mil).
What is the minimum order quantity for custom plastic cards?
Minimum order quantities depend on the printing method. For offset-printed cards, the minimum is typically 1,000 cards due to plate setup costs. Digital printing allows smaller runs from 500 cards with zero setup fees. Silkscreen printing is viable from 500 cards upward. For very small quantities (under 500), digital printing is recommended for the best value.
What file format do you need for plastic card artwork?
A print-ready PDF is preferred, with 3 mm bleed on all edges, CMYK color mode, and 300 DPI minimum resolution. For variable data cards (each card with a unique name, number, or barcode), provide an Excel or CSV data file matched to the PDF template. We also accept AI, EPS, and CDR files. Card templates are provided free of charge upon request.
Can you print on both sides of a plastic card?
Yes. Double-sided printing is standard for most plastic card orders. The front typically carries the primary branding, logo, and cardholder photo area, while the back contains terms and conditions, magnetic stripe, signature panel, or barcode. Both sides can receive full-color CMYK artwork plus lamination. Variable data can be printed on the back as well.
How long does custom plastic card production take?
Standard lead time is 7–12 business days for offset-printed cards and 5–7 business days for digitally printed cards. Additional finishing steps (foil stamping, embossing, chip embedding) may add 2–4 business days. Rush production (3–5 business days) is available with a surcharge. Please confirm rush availability before placing your order. International shipping adds 3–12 business days depending on destination.
What is the difference between HiCo and LoCo magnetic stripe?
HiCo (High Coercivity, 2750 Oe) magnetic stripes are more resistant to accidental erasure from magnets, credit card holders, and metal detectors. They are the industry standard for cards expected to last more than 6 months. LoCo (Low Coercivity, 300 Oe) stripes are easier to encode and read but more susceptible to demagnetization, suitable for short-term use cards like hotel keys or conference badges. HiCo is recommended for gift cards and membership cards with long lifespans.
Can you print contactless IC cards for hotel key systems?
Yes. We produce contactless IC cards compatible with MIFARE Classic, MIFARE Plus, MIFARE DESFire EV2/EV3, and ISO 15693 standards. These are commonly used for hotel key cards, building access control, and transit passes. We embed the RFID/NFC antenna and chip within the card body during the lamination process. Pre-programming and encoding of sector data can be done to your specification or we supply blank pre-laminated cards for on-site encoding.
Do you offer pre-production samples before bulk orders?
Yes. Pre-production samples using your selected substrate, printing method, and finishing options are available. The sample fee is fully refundable against the full production order. Samples allow you to evaluate color accuracy, card thickness, lamination finish, lamination adhesion, and encoding functionality before committing to the full print run. We recommend samples for any first-time project or complex card design.
What is the typical lead time for custom-shaped cards?
Custom-shaped cards require a dedicated die to be manufactured for the card cutter. Die creation takes 3–5 business days and involves a one-time die charge. After the die is ready, production takes the same 7–12 business days as standard-size cards. Custom shapes are available for most card types: gift cards, key tags, loyalty cards, and promotional items. Minimum order for custom shapes is typically 2,000 cards to amortize the die cost.
Are eco-friendly or biodegradable plastic card options available?
Yes. We offer PET (recyclable polyethylene terephthalate) and eco-composite biodegradable card materials. PET cards are fully recyclable through standard plastic recycling streams and provide comparable durability to PVC. Eco-composite cards use PLA/PHA plant-based polymer blends and are certified compostable under industrial composting conditions (EN 13432). Note that magnetic stripe and IC chip components may reduce recyclability for cards carrying functional elements.

Why Choose ZXC Print for Plastic Card Printing?

Since 1998 Over 25 years of commercial printing expertise, from simple membership cards to complex contactless smart cards with refined finishes
Heidelberg Offset & Dedicated Card Equipment In-house presses, die-cutters, silkscreen machines, laminators, and encoding stations for end-to-end control
Full In-House Encoding & Finishing Magnetic stripe encoding, IC chip bonding, barcode printing, foil stamping, embossing, and scratch-off panels, all done on-site
High-end Finishes Gloss/matte/soft-touch lamination, spot UV, hot foil stamping, embossing, and custom numbering for high-end card programs
Worldwide Shipping International delivery to North America, Europe, Asia, Australia, and the Middle East, with drop shipping available
Dedicated Project Manager One point of contact from artwork preparation and pre-production proofing through to printing, encoding, finishing, and delivery

Ready to Print Your Plastic Cards?

Request a free quote or speak with our plastic card printing specialists about your project specifications: card type, quantity, size, substrate, printing method, and functional requirements.

Get a Free Quote Contact Us