At first glance, the average modern ID card might look simple, but its creation involves a precise blend of engineering and advanced materials science. Found in offices, universities, and government buildings, these cards act as secure credentials while also carrying an organisation's branding, with roughly 37 billion produced worldwide each year.

In this field, manufacturing choices make all the difference, determining whether an ID card can stand up to years of use while resisting tampering. In this article, we examine that while many look the same, they're often very different.

What Is The Global ID Card Standard?

So, what standard is it that ID cards should adhere to? The International Organization for Standardization sets out physical requirements under ISO/IEC 7810 for the ID-1 format — the same size that's used for bank cards.

These guidelines outline the size, flexibility, and resistance to bending of your cards, as well as their temperature, humidity and chemical exposure tolerances to ensure your cards will work reliably in all sorts of environments.

However, it's the manufacturing choices that are made beyond these basics that really determine whether you end up with a low-cost card that wears out quickly or a secure credential built to last.

UK Compliance: More Than Just ISO Standards

While ISO standards provide the international framework, UK businesses face additional layers of regulation that can significantly impact both material choices and manufacturing processes. The Equality Act 2010 means ID card systems must be accessible to users with disabilities — affecting everything from card thickness to colour contrast ratios for printed elements.

For public sector organisations, the Public Contracts Regulations 2015 add procurement requirements that can influence supplier selection and material specifications. And if your cards will store personal data — whether in chips, magnetic stripes, or even printed form — UK GDPR creates data controller obligations that stretch from manufacturing through to end-of-life disposal.

Different UK sectors bring their own requirements too. NHS identity cards must meet NHS Digital specifications, while cards for government contractors may need to align with Cabinet Office security policies. Educational institutions often have safeguarding requirements that influence both the data stored and the visual design of student cards.

Stage 1 — Selecting the Right ID Card Materials

When creating any new ID card, the first decision that must be made is your choice of substrate. It's a crucial detail because the selection you make is going to impact not just how durable the end product is, but also how well it takes print and how fraud-secure it is.

The 3 main types of substrate include:

  1. PVC — polyvinyl chloride — is the most common choice for everyday ID cards. It's flexible, smooth, and takes printed colour well, making it suitable for staff passes, visitor badges, and other low-security applications.

  2. PETG, or polyethylene terephthalate glycol, is less likely to crack and wear out. It's often selected for cards handled every day or used in harsher environments, while still delivering strong print quality.

  3. Polycarbonate (PC) is typically reserved for high-security documents such as driving licences. Its layered, adhesive-free construction makes tampering easy to detect, and in many cases, these cards remain in service for over a decade.

Material selection is not purely about appearance or budget. It dictates which security features can be embedded, such as holograms, microtext, UV printing, or contactless chips, and how well those features will hold up over time.

Environmental and Supply Chain Considerations

The UK's evolving Extended Producer Responsibility regulations are pushing organisations to think beyond the card's active life. Forward-thinking businesses are already choosing materials that align with circular economy principles and considering take-back schemes for expired cards.

Post-Brexit supply chain changes have also affected material availability and costs. UK businesses now need to factor in UKCA marking requirements for electronic components and plan for potential supply disruptions. This makes the choice of substrate even more critical — you want materials that are both readily available and compliant with UK standards.

For organisations with sustainability commitments, the environmental impact of different substrates varies significantly. PVC recycling infrastructure is well-established in the UK, while newer bio-based alternatives are emerging for organisations with net-zero targets.

Durability and Security by Design

A card's lifespan is largely determined before any ink is applied. While PVC is perhaps the most cost-effective option, it will usually only last 3 years of daily use before it needs to be replaced. The next most durable is PETG (up to 5 years), and the hardiest is polycarbonate (up to 10 years).

Why the difference? Each material is designed for different uses. The stronger the material, the more resistant the card is going to be to warping, or wear and tear caused by constant swiping. For secure IDs, layering techniques add another level of protection.

Choosing the Right Substrate Matters

For example, with polycarbonate cards, different layers may be used to hold printed imagery, embedded data chips, or laser-engraved personal details. Because these layers are fused under heat and pressure rather than glued, any attempt to peel them apart will visibly destroy the card's surface.

The choices you make at this stage determine how things go during the next part of the process: printing, personalisation, and finishing — the steps that transform a plain card blank into a fully functional identity document.

UK Climate and Usage Considerations

UK weather conditions add another dimension to durability planning. Cards used outdoors — like those for construction sites or university campuses — need to withstand everything from Scottish winters to London heat waves. The temperature cycling can be particularly hard on cheaper materials, leading to warping or delamination that makes cards unreadable.

For cards that include payment functionality, Payment Card Industry (PCI) standards as interpreted by UK financial regulators add security requirements that go well beyond basic identification. These cards need to maintain their integrity even when subjected to the kind of daily abuse that comes with being used as both an ID and a payment method.

Stage 2 — Printing, Layering, and Finishing

Once you've selected the right substrate for your requirements, the next part of the process is to turn it from a small blank rectangle into a personalised, functioning ID. This is where the card gets its visual branding, as well as its security, machine-readable features.

In the ID card sector, three printing methods are employed:

  • Dye-Sublimation Printing — This uses heat to transfer dye directly into the card's surface. It's a technique able to produce smooth gradients, sharp images, and vibrant colours, making it ideal for photo IDs. Dye-sub is compatible with PVC and PETG cards.

  • Retransfer Printing — This practice involves applying the required image to a clear film, rather than it going straight onto the card. The film is fixed to the card using heat and pressure. This bonds the two together and gives a full-coverage finish that holds up to daily use.

  • Laser Engraving — For polycarbonate security cards, a laser cuts text, photos, or patterns into the inner layers. Any attempt to remove or change them leaves clear, visible damage.

The approach you choose depends on how the card needs to look and the level of protection it requires. From here, it moves on to the final stage, where coatings and extra security elements are added.

Data Protection During Manufacturing

UK GDPR compliance starts during the printing process, not after the cards are delivered. Any personal data being printed, encoded, or embedded creates data controller obligations for both the card issuer and the manufacturing partner. This affects how long production files can be retained, what security measures must be in place during manufacturing, and how waste materials containing personal data are disposed of.

For organisations in regulated sectors, additional requirements may apply. Counter-Terrorism and Security Act 2015 duties can influence ID card policies in universities and other specified authorities, affecting both the security features required and the processes for issuing and managing cards.

Stage 3 — Integration of Layering and Security

By now, the card has its dimensions and its printed face, but the build isn't finished. For IDs that need higher security, there's a stage where extra layers and features are introduced, some visible, others not so obvious.

A clear overlay film might be applied to reduce fading over time and guard against surface scratches. In other cases, you'll see a holographic patch added, instantly recognisable to the eye yet extremely hard to replicate.

A Range of Features Can Be Added

If the card has to carry out more than just identification, the necessary electronics are added here. That could be a contact or contactless chip, a magnetic stripe, or even a coiled antenna so it can be tapped against a reader.

Then there are the features you'd never notice unless you knew they were there: UV printing and microtext designed to sit quietly in the background, waiting to expose a counterfeit.

None of this is done in a back-room print setup. It happens inside secure manufacturing facilities where every piece of material is checked in, tracked, and accounted for until it leaves as part of a finished card.

For a look at how these security features are tested in practice, see our article on detecting fraudulent documents.

UK Security Classifications and Integration Requirements

Cards used in government environments may need to align with the Government Security Classifications Policy, which can influence everything from substrate choice to the type of security features embedded. For contractors working on sensitive projects, these requirements aren't optional — they're often written into the contract terms.

The UK's push toward digital identity verification is also creating new integration requirements. Modern cards increasingly need to work alongside mobile credentials and digital wallets, which means thinking about NFC pairing capabilities and QR code integration during the design phase.

For workplace cards that include payment functionality, integration with UK banking systems adds another layer of complexity. These cards need to work seamlessly with everything from office coffee machines to London's transport network, requiring careful attention to contactless payment standards.

Stage 4 — Quality Assurance

Once layering has been done, the cards go through their final checks. That might mean running a chip through a reader, checking print alignment, or feeling the edges for any lifting or gaps. A card that fails here isn't reworked; it's destroyed.

How far those checks go depends on the type of card. A day-pass for a visitor isn't treated like a government-issued driving licence, but both will be examined closely enough for their purpose before they're signed off.

UK-Specific Quality Standards

For suppliers working with UK public sector organisations, quality assurance often needs to demonstrate ISO 9001 certification and robust audit trails. The documentation requirements can be extensive, particularly for high-security applications where chain of custody records may be required for years after the cards are issued.

Professional indemnity insurance is increasingly expected for suppliers handling sensitive data, while product liability considerations become important for cards used in safety-critical applications. These aren't just nice-to-have extras — they're often written into procurement requirements.

Choosing an ID Manufacturing Partner You Can Trust

From a simple staff badge to a high-security national ID, the physical build of a card determines its usefulness and resilience. The right combination of substrate, printing, layering, and security features not only ensures the card functions as intended but also protects the issuing organisation's brand and security posture.

As counterfeiters become ever more sophisticated, the industry will need to continue to innovate and create cards that can't be reproduced or tampered with. Understanding these processes helps you make informed choices that balance cost, durability, and security.

For a broader perspective on the legal landscape around counterfeit documents, see our article on what the law really says about counterfeit ID cards.

UK Market Expertise Matters

For UK organisations, choosing a manufacturing partner means finding someone who understands not just the technical requirements, but also the regulatory landscape. They should be able to navigate everything from Trading Standards requirements to sector-specific regulations, while maintaining the security standards your organisation needs.

Look for suppliers who can demonstrate experience with UK compliance requirements and who carry appropriate insurance coverage. They should be upfront about their audit processes and able to provide references from similar organisations in your sector.

Compliance Note: This content covers general manufacturing processes and regulatory considerations. Specific compliance requirements vary by sector and application. For detailed guidance on your particular use case, consult with specialists who understand both the technical and regulatory requirements for your industry.

References

  1. ISO — ISO/IEC 7810:2003 – Identification cards — Physical characteristics
  2. Entrust — What Are PVC ID Cards and Printers?
  3. Thales Group — Choosing the Best Substrate for Driver's Licenses and IDs
  4. Magicard — Dye Sublimation ID Card Printing
  5. HID Global — Retransfer ID Card Printers
  6. Thales Group — Laser Engraving for Secure ID Documents
  7. Mühlbauer Group — Security Features for ID Cards
  8. In Groupe — National ID Card Manufacturing Process