There are two types of printing ID cards using plastic ID card printers. Thermal transfer printing and dye sublimation printing are options available to be used in direct to card print or retransfer printers. Direct to card print burns the image directly on the card surface. Retransfer printing deposits the image on the back of a clear plastic film. The film is then bonded to the surface of the plastic card. Retransfer printing is a newer method of printing and many like it better as the image can be applied to specialized cards and do not require a perfectly smooth card for a great image result. Photo ID printer systems may utilize the thermal transfer or the dye sublimation method of printing.
Thermal printing works because resin or was based ink is melted off of the printer ribbon and is transferred directly to the surface of the card or to the retransfer film. The ribbon needs a printhead to provide best results. The printhead is a unit that has many heated pins aligned across a ceramic plate. Each pin receives instructions to heat and release ink at just the right sequence to recreate the digital image that the ID card softare displays on the computer monitor. The printhead and card are held stationary as ribbon panels pass between the two and release colors according to the printhead's heated pins.
Colored photos and logos require the use of Y, M C and K panels in the ribbon. The panels each pass over the card one after the other. Each panel releases dots of color as it passes resulting in the completed image. Dithering is used to put the dots of different colors close together to create a blended shade of any color when looked at by the human eye..
Monochrome printing is also used in thermal printing. This type of ribbon produces clear results on items such as bar codes, that can be machine readable. Single color printing is completed at high speeds making customization of a preprinted card a viable option for many situations. Thermal ribbon is durable and resists fading. The resin drys quickly. It can also be applied to specialized paper cardstock.
Dye Sublimation
Sublimation means that a solid due is headed directly into a gaseous state. The dye never becomes a liquid during the process. The dye is heated to about 250 degrees Fahrenheit. At that point, the polymers in the PVC card needs to be headed to about 350 degrees. The gaseous dye can then penetrate the plastic. Then the card cools down the dye has saturated the plastic and bonds chemically with the card.
Cards that are printed with dye sublimation images are crisp and sharp. The photographic images are printed with accuracy. With higher heat levels, the more dye is released onto the card surface. This process allows great control over the opacity and transparency of the print. The colors blend into a pleasing result.
Colors in this printing method are applied one panel at a time- the Y, M and C. This type of print is prone to fading when exposed to UV rays from the sun. Often a UV resistant topcoat is recommended to help protect the dye printed cards.
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