Production of Laminated Cards for High-End Applications ICMA – Expo 2008 Orlando, 06th – 09th April Presented by: Thies Janczek

COCASO1 April, 08th 2008 ICMA Expo, Orlando Content  Introduction  Physical and Data Security  Card Production Considerations  Markets and Application  Summary

COCASO2 April, 08th 2008 ICMA Expo, Orlando Introduction  ID cards in ID-1 format are around for decades  Increasing employment of Chip Cards for ID card issuer (contact and contactless)  Contactless technologies either pure or DIC  Specifications ICAO 9303 (ISO/IEC 7501) for Machine Readable Travel Documents (MRTD) ECC (European Citizen Card) CEN/TS European Driver license

COCASO3 April, 08th 2008 ICMA Expo, Orlando Introduction Security Categories Overview Second line inspection Educated personel, Police, Immigration Simple tools, e.g. UV Lamp UV-VIS Lumineszens, IR-VIS Lumineszens Machine readable features Third line inspection Forensic Analysis e.g. Spectral Analysis Police laboratoriesIR-IR Lumineszens, Reactive agents First line inspection everybodyWithout tools Guilloch, Hologram, Optical Variable Ink, Changeable Laser Image Who How What

COCASO4 April, 08th 2008 ICMA Expo, Orlando Physical and Data Security  Data structure defined in ICAO 9303 for travel documents  Crypto controller employed with a high level of data security and chip hardware security  Physical aspects of a security printed product to be fullfilled (mainly 1st and 2nd line inspection)

COCASO5 April, 08th 2008 ICMA Expo, Orlando Physical Features Guilloche printing  Correct Design:  Continuous fine lines  Spot colour (difficult to copy)  Rainbow printing Magnification

COCASO6 April, 08th 2008 ICMA Expo, Orlando Physical Features Mikro printing

COCASO7 April, 08th 2008 ICMA Expo, Orlando Physical Features Optical Variable Ink (OVI) „transprent“ Screen ink 5 nm Cr MgF 2 30 nm Al MgF 2 5 nm Cr Thickness of MgF2 layer Defines color change (gold-green; green-magenta; green-black etc.) Flakes of di-electric layers (Fabry-Perot) in a matrix of silk screen ink

COCASO8 April, 08th 2008 ICMA Expo, Orlando Passport Driving license ID card Car documents PC (PVC) transparent Offset or Screen PC (PVC) white or paper Laser engraving Non tactile Laser Physical Features Laser Engraving Laser engraving tactile

COCASO9 April, 08th 2008 ICMA Expo, Orlando Physical Features Relief imprint

COCASO10 April, 08th 2008 ICMA Expo, Orlando Fluorescent filaments Fluorescent Guilloch Fluorescent color (various) Rainbow Printing with UV-colors Physical Features - unvisible Photolumineszent

COCASO11 April, 08th 2008 ICMA Expo, Orlando Construction generals Laminated Card  Multilayer Construction preferred w/o adhesive Opaque inner layer Transparent overlay layer  Functional layer (basically overlay)  Limitation OV thickness through module dimensions Contactless inlays Interlayer printing (water mark) Fitting front/reverse side

COCASO12 April, 08th 2008 ICMA Expo, Orlando Card Production Considerations  Pre-Press  Printing  Collation  Lamination  Punching  Milling and Embedding  Personalization

COCASO13 April, 08th 2008 ICMA Expo, Orlando Card Production Considerations Pre-Press  Artwork generation is not allowed on commercial available software  Special software ( > 40k Euro) to be employed Experience personal  No process colours Various visible and unvisible inks high securtiy area and system (server)

COCASO14 April, 08th 2008 ICMA Expo, Orlando Card Production Considerations Printing  Multiple custom colours in offset visible and unvisible  Screen printing for OVI  Tight register due to fine line artwork  Rainbow printing (visible and unvisible) sheet orientation (repeat)  Print machine limitations  Temperature stable colours to be used

COCASO15 April, 08th 2008 ICMA Expo, Orlando Card Production Considerations Collation  Hologram under Overlay possible Holographic stripe  Front/Reverse side registration  Contactless inlay (antenna)?  > 6 layer construction possible manual collation in most cases material handling

COCASO16 April, 08th 2008 ICMA Expo, Orlando Card Production Considerations Lamination  Longer lamination cycles with PC w/o adhesive layers capacity decrease  High temperatures sensitivity Hologram material printing colours  colour shift  bleeding

COCASO17 April, 08th 2008 ICMA Expo, Orlando Braille Lettering Positioning Pins MLI/CLI Card Production Considerations Lamination plates  Structured lamination plates expensive structuring process set per project registration to printed artwork special surface treatment  anti adhesion  hardening  Just a few supplier with specialised technologies

COCASO18 April, 08th 2008 ICMA Expo, Orlando Card Production Considerations Punching  Standard registration w/ print marks White border (?)  Tool has to be fit to the material PC more difficult and higher wear of tools Dimensions Edges and burrs Handling scratches Positioning precision (w/ inlays)  more precise tooling and set up for multi material constructions

COCASO19 April, 08th 2008 ICMA Expo, Orlando Card Production Considerations Milling and Embedding  Milling parameter to be adjusted to the material combination  Equipment limitations for some DIC technologies  Module adhesive to be fitted to core material

COCASO20 April, 08th 2008 ICMA Expo, Orlando Card Production Considerations Personalization  Laser engraving is the most employed gray scale system tactile and non-tactile MLI/CLI posibilites to be integrated  new materials developed with receptor coatings for D2T2 and Re-transfer (colour)  New technology developed for continuous ink jet printing (colour)  Data handling and processing with special security (e.g. HSM)

COCASO21 April, 08th 2008 ICMA Expo, Orlando Markets and Applications  Governmental projects demand physical security features ID-card, Driving license, Citizen Card, Passport (data page) Worldwide necessity for Machine Readable Travel Documents Long term acquisition for long term contracts  Commercial projects are more focussed on IT technology Single Card Digital printed

COCASO22 April, 08th 2008 ICMA Expo, Orlando Example German driving license Optical Variable Ink Throughlight register Mikrotext Tactile Laser Engraving Holografic thread with demetallised Mikrotext Changeable Laser Image Paper field

COCASO23 April, 08th 2008 ICMA Expo, Orlando Example Swiss ID card Kinegram with demetallised Microtext individual Card number Tactile Laser engraving Mikrotext Guilloche Line Strukture OCR text Fluorescent Security threat Changeable Laser Image UV-Iris pint Relief Motive

COCASO24 April, 08th 2008 ICMA Expo, Orlando Summary  Dedicated Know How is needed Artwork generation Card construction and features Personalisation  Special Equipment / Modifications Pre-Press, Collation, Lamination, Punching, Personalization  Marketing and Sales to be prepared for long term aquisition

COCASO25 April, 08th 2008 ICMA Expo, Orlando THANK YOU FOR YOUR ATTENTION Production of Laminated Cards for High-End Applications More Information: COCASO – Thies Janczek – Moewenstrasse 5a – Molfsee – Germany Phone: +49-(0) –

COCASO26 April, 08th 2008 ICMA Expo, Orlando