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PET Prelams Specifications – Standard DEFINITION Standard Prelam is a patented prelaminate product manufactured by CompoSecure, LLC in Somerset, NJ, USA that utilizes biaxially oriented polyester material. This product extends the standard life of a plastic card from three years to ten years. Standard Prelam is a buffered polyester that enhances the bond between Polyester and PVC. This results in a card that withstands even severe service testing. Unbuffered polyesters do not withstand this level of service testing and remain intact. Standard Prelam costs less due to the lower content of polyester materials. Since the strongest part of the structure is at the outer surface (similar to an I Beam), maximum benefit for card life and strength is achieved.
AVAIL ABLE STANDARD PREL AM PRODUCTS This clear PET composite material is available in sheet or roll form. This replaces laminating film and runs on standard card manufacturing equipment. It is offered in the following configurations:
Product Code
Thickness
PL3C
.003”
75 MICRONS
PL5C
.005”
125 MICRONS
PL5W
.005”
125 MICRONS
PL6C
.006”
150 MICRONS
PL6W
.006”
150 MICRONS
PRODUCT NOTE Product codes ending with “C” denote clear Prelam materials. Product codes ending with “W” denote translucent white materials (white buffer one side). White Prelams are generally used for 2D barcode applications, and as a replacement for projects that currently use white polyester products. Z Axis failure normally seen in cards manufactured with white PET is eliminated with the used of white Prelam. Please note that special attention must be paid to the opacity of the white PVC center core to ensure ISO compliance, due to white Prelam’s translucency. White Prelams are suitable for all printing applications.
PERFORMANCE CHAR ACTERISTICS* One sheet of PL5 laminated on either side of a solid PVC core (2 sheets of PL5) yields an 8 year card life (20% polyester content). One sheet of PL5 laminated on either side of a solid PVC core (2 sheets of PL3) yields a 5 year card life (8% polyester content). One sheet of PL6 laminated on either side of a solid PVC core (2 sheets of PL6) yields a 10 year card life (27% polyester content). *Card life is based upon an identification card used under normal circumstances.
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CompoSecure, LLC 500 Memorial Drive, Somerset, New Jersey 08873 Phone 908.518.0500 Fax 908.518.0569 composecure.com
PET Prelams Specifications – Standard APPLICATIONS Standard Prelams should be used in any plastic card application where durability is a concern. Identification cards like Driver’s Licenses and National ID Cards are a natural fit for this product. Special Issue Financial cards are also an ideal application for Prelam products.
ECONOMICS/PRICING The purchase price of Standard Prelam may be comparable to other available polyester materials, but there are substantial savings in the manufacturing process when using Standard Prelam. Rather than adding thicker polyester to a sheet buildup with multiple layers, Standard Prelam allows you to minimize the number of layers and increase the amount of lower cost material, PVC. Minimum order size is 1000 sheets, or 1000 linear feet (roll form). Volume pricing for annual contracts is available upon request.
SCIENTIFIC DATA An independent technical laboratory’s tests have yielded the following results with cards produced using one sheet of Standard Prelam (PL5C) laminated on either side of a solid PVC core:
»» Flex testing showed no fracturing along the A or B Axis until an average of 500,000 flexes. »» Passed the Falling Dart Impact Resistance test. »» Passed the Card Structure Integrity Test. This included humidity, corner impact and shaker tests. OTHER INFORMATION Standard Prelam products are not meant for use with card designs that include inks that bleed off the edge of the card. Prelams for bleeds are available upon request. PL3CL is a great choice for RFID applications; it adds the durability of PET when used as the outside skins of the card structure, thus adding longevity to cards containing costly RFID modules. With the use of these Prelam products, plastic card manufacturers can include embedded security features such as custom holograms, OVDs and holographic stripes, which are custom. With use of these Prelam products, plastic card manufacturers can include embedded security features such as holograms, OVDs and holographic stripes. Not recommended for buildup where 1 sheet is placed in the center of the sandwich.
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CompoSecure, LLC 500 Memorial Drive, Somerset, New Jersey 08873 Phone 908.518.0500 Fax 908.518.0569 composecure.com
PET Prelams Specifications – Standard ENHANCEMENTS FOR STANDARD PREL AMS The following product enhancements are available for Standard Prelam products.
Product/Description
Features
Benefits
PL5C-M: Magnetic Stripe
A .005” (125 mircons) Prelam with a low or high coercivity magnetic stripe applied in register. This item is available in sheet or roll form. This product is available in sheet or roll form.
This product allows for automation of the magnetic stripe application process, while yielding a 10-year life card, i.e. can run on standard Industry wide “gathering” equipment.
PL6C-M: Magnetic Stripe
A .006” (150 microns) Prelam with a low or high coercivity magnetic stripe applied in register. This item is available in sheet or roll form. This product is available in sheet or roll form.
This product allows for automation of the magnetic stripe application process, while yielding a 10-year life card, i.e. can run on standard Industry wide “gathering” equipment.
Custom Prelam
Custom Prelams designed to customer specifications
One-of-a-kind security products which are not available in the marketplace.
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CompoSecure, LLC 500 Memorial Drive, Somerset, New Jersey 08873 Phone 908.518.0500 Fax 908.518.0569 composecure.com
Standard Prelam Product Line Specification Sheet: PL5C, PL6C, PL5W, PL6W, PL3C MATERIAL USAGE INTENT To create premium quality, highly durable plastic cards (primarily used for I.D. applications) that will surpass high humidity and stress crack environmental testing far better than any commercially available product. These products are not meant to be substituted for standard bleed film overlay in cases of full ink bleeds on plastic cards and are not meant for applications where card embossing is required. Laser marking and ablation personalization should be tested on sample card build-ups, with job specific ink draw-downs. Please note that the white Prelam uses a white buffer on one side only and is therefore translucent, not opaque. Special attention should be paid to the opacity of the PVC core stock used with the white Prelam to ensure compliance with ISO opacity specifications.
COMPOSITION Clear biaxially oriented Polyester with buffer compound designed to platen laminate to PVC. This product can also be substituted for the PVC outer layer of the final card construction. It will accept Dye-Diffusion thermal transfer printing (D2T2) as well as tipping foil.
THICKNESS Currently .003” (75 microns), .005” (125 microns) or .006” (150 microns) + or – 10% are available, but custom thicknesses are available on request.
FORM FACTOR Sheets or rolls are available. Sheet tolerances are + or – 1/16” (1.6 MM) on diagonals and rolls are + or – 1/32” (.8 MM) on width. Weight per roll or container by customer agreement.
L AMINATION/PL ATEN TEMPUR ATURE Optimally laminates at 15 degrees Fahrenheit higher platen temperature than standard PVC. Adding 10% to temperature and pressure may yield better results. Since each laminator is unique, testing is required to find the best parameters for your equipment.
DIECUTTING Cuts more smoothly than PVC.
HEAT RESISTANCE In card form, the maximum heat distortion temperature is approximately 220˚ Fahrenheit (104.44 ˚ Celsius) when platen laminated at the highest possible temperature to Homopolymer PVC.
STOR AGE RECOMMENDATIONS Store in original containers in a cool, dry warehouse.
SPECIFIC GR AVIT Y 1.45 ± 5% Please refer to the MSDS for safety and handling precautions. Please contact your CompoSecure representative for more detailed operating and testing procedures at (908) 518-0500.
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CompoSecure, LLC 500 Memorial Drive, Somerset, New Jersey 08873 Phone 908.518.0500 Fax 908.518.0569 composecure.com
Polycarbonate Composite Product Line DEFINITION Polycarbonate Composite Prelam is a patented prelaminate product manufactured by CompoSecure, LLC that contains laser reactive Polycarbonate. Using CompoSecure’s materials science technology, our Polycarbonate Composite Prelam enhances the security of documents such as ID cards and E-Passport Bio-pages. During laser personalization, the Polycarbonate material is altered at the molecular level. This transforms the material itself by turning particles into carbon, which means that would-be counterfeiters destroy the secure document itself if forgery is attempted.
AVAIL ABLE OPTIONS The following product option is currently available:
Product Code
Description and Form Factor
PL5PC
.005” laser reactive Polycarbonate Composite, available in roll or sheet form.
PERFORMANCE One sheet of .005” (125 microns) PC Composite Prelam is placed as the outside skins of a standard .030” (750 microns) buildup. White PVC is printed (.020” [500 microns] or some combination thereof) and laminated in the center of the two Prelam sheets. Generally, white PVC or some combination of PVC and/or PET is used for the center of the laminated sheet. Due to the fact that the PC Composite Prelam utilizes humidity resistant materials, secure documents withstand ISO 10343 severe service prolonged humidity tests. In contrast, secure documents fail the prolonged humidity test (layers separate and the document falls apart) when industry standard adhesive coated PC is used, due to the fact that the adhesives are water-based.
APPLICATIONS PC Composite Prelam is ideally suited to create Driver’s Licenses, National ID Cards, E- Passport Bio-pages, as well as other secure document applications.
ECONOMICS / PRICING While the purchase price of PC Composite Prelam is comparable to other Polycarbonate based materials, the real savings occurs with its ease of use. With the use of PL5PC, lower cost center core substrates may be used, such as PVC. This leads to a less costly document without sacrificing security and durability, as compared to a 100% PC document. In addition, standard industry equipment, such as collators and laminators, may be used at standard PVC lamination cycles to laminate this material. Standard die-cutting equipment is also compatible with this product.
MORE INFORMATION / CONTACT Please contact CompoSecure directly for pricing based upon your custom specifications. Minimum order size is 1000 linear feet. Custom PC Composite Prelam thicknesses and compositions are available, including Laser Reactive Polycarbonate sub- surface, D2T2 Printable surface, as well as polyester durability enhanced.
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CompoSecure, LLC 500 Memorial Drive, Somerset, New Jersey 08873 Phone 908.518.0500 Fax 908.518.0569 composecure.com
PC Composite Prelam Specification Sheet (Laser Reactive) MATERIAL USAGE INTENT To create premium quality, highly durable plastic secure documents (Driver’s Licenses, ID Cards, E-Passport Bio-pages) that will surpass high humidity and stress crack environmental testing far better than commercially available products.
COMPOSITION Laser Reactive Polycarbonate composite material designed to platen laminates to substrates such as PVC, PET, PC and other materials. This product must be substituted for the PVC outer layer of the final card construction.
THICKNESS Currently .005” (125 microns) + or – 10% is available, but custom thicknesses and combinations are available upon request.
FORM FACTOR Rolls and sheets are available. Sheet tolerances are + or – 1/16” 1.6mm on diagonals and rolls are + or – 1/32” .8mm on width.
L AMINATION / PL ATEN TEMPER ATURE Optimally laminates at the same temperature as standard PVC.
DIECUTTING Cuts on standard PVC dies.
STOR AGE RECOMMENDATIONS Store in original containers in a cool, dry warehouse.
SPECIFIC GR AVIT Y 1.45 ± 5%
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CompoSecure, LLC 500 Memorial Drive, Somerset, New Jersey 08873 Phone 908.518.0500 Fax 908.518.0569 composecure.com
