Metal cards are a popular way for payment card programs to recognize premium cardholders. Their weight and rigidity, partnered with sophisticated design, moves them to the top of cardholders’ wallets as an eye-catching means of signaling elite status. Consumers value the availability of these exclusive and substantial cards. A recent survey found that 58% of US surveyed consumers indicated that the availability of metal cards positively impacts their brand perception of a financial institution.
Metal card manufacturing requires special considerations that differ from the production of traditional plastic PVC cards. There are choices to be made about the type of metal construction, personalization techniques, fulfillment strategies, and the overall price of fully finished cards.
The journey from concept to construction to delivery can be more complex than most payment card program managers realize. Understanding the intricacies of this process and the decisions required along the way is what separates a successful metal card program from one that experiences costly delays. Here’s what to know before you build.
Metal payment card construction types
There are various ways to construct metal credit cards and debit cards, all of which have an impact on manufacturing, personalization, and fulfillment. Here are three of the most common construction types.
1. Solid Metal (Full Metal Core)
Solid metal payment cards, also referred to as full metal core, are typically constructed using titanium, stainless steel, or aluminum alloy plate. Solid metal cards do not contain a PVC core and therefore no antenna is embedded to conduct contactless transactions. Some full metal core cards may include a thin polymer backplate or an antenna overlay to support contactless signal transmission.
For cards without an antenna, the EMV chip is embedded directly into the metal substrate and the card must be inserted into the card reader for point-of-sale payments. This requires special milling and insulation around the chip cavity. An encapsulated chip/antenna combination module may also be an option for supporting contactless transactions. Adding cardholder details during the personalization process is achieved by laser engraving or chemical etching.
Full metal core provides the weightiest finished product at approximately 25 grams per card versus a weight of approximately 5 grams for PVC cards. They are highly durable and rigid, with a unique look and feel. Achieving this finished product requires an investment that can exceed $25 per card, making it a significant expense for large card portfolios.
2. Metal Veneer (Composite Core)
Metal veneer cards feature a thin stainless or aluminum sheet laminated to a standard PVC body. Using a plastic substrate for the card core allows for standard chip embedding and personalization of cardholder details.
The front metal veneer gives the card a metallic appearance and heftier weight while maintaining its contactless capabilities via the non-metal rear layer. While less substantial than full metal cards, metal veneer creates a premium look and feel while remaining compatible with standard card manufacturing equipment. Metal veneer cards are also less costly to manufacture, at a price of approximately $15 per card.
3. Heavy Metal Inlay (with PVC Body)
Heavy metal inlay cards feature a full PVC card body with a metal slug or inlay plate (commonly made of stainless steel or tungsten) that is inserted in the center core. The inlay is pressed between plastic layers during lamination and is die-cut on a standard CR80 card punch. Dual-interface capabilities are maintained as with full plastic construction, supporting both contact and contactless payments.
Heavy metal inlays are a cost-effective way of delivering a dense, solid feel at a more manageable price point. Prices vary, but the typical cost is approximately $10-15 per card.
A metal look doesn’t always require a metal card
For programs that want the prestige of a metal card without the cost and complexity, there are meaningful alternatives worth considering.
There is a category of cards that provide the metal experience without using any metal. Thanks to materials and techniques including foil, chrome-plated PVC, UV spot accents, and metallic inks, a metal finish or metallic components can be simulated with advanced printing and construction techniques.
While lacking the density and weight of true metal cards, non-metal alternatives can deliver the metallic effect at a fraction of the price (typically $1-3 per card) while using standard card construction workflows and equipment.
This isn’t a budget compromise; it’s a deliberate program decision. Some of the most effective premium card programs use highly specialized PVC construction because it gives them more control over color, design, and personalization while staying within budget.
Personalization for metal cards
Personalizing metal cards with account holder information (PAN, expiration date, CVV, etc.) requires special considerations. The personalization process, whether laser engraving, chemical etching, or digital printing, may require special equipment, calibration, and workflows for metal substrates. In addition, turnaround time for metal cards may be lengthier than standard PVC cards due to these special production processes.
Elevating fulfillment for metal cards
Premium cardholders expect premium experiences, right down to how their payment cards are delivered. A high-end, thoughtfully designed metal card may demand premium packaging as well. Bespoke carriers, specialized activation messaging, and sophisticated packaging is an important consideration for the end customer experience and can materially impact total customer acquisition costs.
In our experience, including manual fulfillment for entry level “premium packaging” (excluding the package itself) and the cost of personalization and fulfillment (excluding the cost of postage), is typically +/-10% of the base card cost.
Selecting the right card manufacturing partner
Metal card programs succeed or struggle based on decisions made before a single card is produced. Material selection, construction specifications, personalization workflow, and fulfillment models are critical program decisions.
Your card manufacturing partner should walk you through the intricacies of a metal card program, including special considerations for personalization and fulfillment, and the impact that metal card production will have on manufacturing volumes, reorder cycles, and delivery SLAs.
ABCorp engages with card programs using a consultative approach, translating business objectives into card specifications that perform under pressure. Whether that means a heavy metal inlay for a flagship product or advanced print techniques on a premium PVC card, we always start by understanding what your card program wants to achieve for its cardholders. Ready to talk through your metal card program? Contact ABCorp.
