How Instant Issuance Payment Cards Are Printed: Retransfer, Direct-to-Card, and the Role of Central Manufacturing 

A person walks up to your branch counter, opens a checking account, and walks out five minutes later with a branded debit card ready for immediate spending. This moment might seem simple, but there are many choices leading up to the interaction that influence the instant card issuance experience at your financial institution. A primary decision is how that payment card gets printed and personalized. This influences the card’s overall look, durability, and timeliness in handing a ready-to-use payment card to its owner. 

The ability to issue a payment card on the spot matters more than it might seem. Worldpay found that 47% of instantly issued payment cards are used within eight hours of activation. This statistic underscores the fact that facilitating the delivery of a payment card can accelerate speed-to-spend. Hiccups in the card printing and personalization process can slow branch throughput, produce cards with inconsistent quality, and hinder card programs from delivering the best experiences to cardholders.  

There are two main printing and personalization options for instantly issued payment cards: retransfer printing and direct-to-card printing. Both methods deliver unique benefits that can serve the demands of your financial institution’s card program, and both depend on high-quality central manufacturing to supply the card stock. This blog compares the two instant issuance card printing and personalization options, and the critical role that central card manufacturing plays in both.  

Retransfer printing: built for quality and durability 

Retransfer printing is a two-step process. Instead of applying ink directly to the card, the printer first prints the design onto a transparent film that is then transferred onto the card body using heat and pressure. 

That extra step gives retransfer printing an edge in print quality and coverage because the image is printed on film first. In doing so, it can cover the entire surface of the card, including right up to and over the edges, and reach print resolutions up to 600 dpi. According to Evolis, this produces a more polished, professional finish and improves durability over time because the transferred film acts as a layer of protection against the daily wear and tear of personal wallets, POS card readers, and contactless terminals. 

Retransfer printers are also compatible with a wide range of card materials, which makes them a fit for programs that print on anything other than standard smooth PVC. The tradeoff is cost. Retransfer printers and their consumables (a color ribbon plus separate transfer film) run higher than direct-to-card printers, and the two-stage printing and personalization process can require more work from the operator when it comes to calibration and managing consumables. 

For financial institutions issuing branded debit cards and credit cards where color accuracy and edge-to-edge coverage are paramount, retransfer printing is likely the preferred option. ABCorp’s own solution d'émission instantanée offers retransfer printing using blank white cards, with the ability to download and print up to 100 card designs and print those designs horizontally or vertically. This allows a single card printer to support multiple products and brand variations, allowing for a wide variety of finished cards to be printed and personalized on-demand for cardholders.  

Direct-to-card printing: built for speed and affordability 

Direct-to-card printing applies ink straight onto the card surface using a print head, with no intermediate film. It relies on one of two processes: color dye sublimation for full-color designs or monochrome thermal transfer for single-color personalization. 

The benefits are significant. Direct-to-card printing is fast, the printers tend to be easy to operate, and the cost of both equipment and consumables is more affordable than that of retransfer printers. It’s a practical option for branches that need to print cards quickly without a steep learning curve for staff. 

However, there can be tradeoffs with the quality of the finished cards. The resolution of direct-to-card printing tops out around 300 dpi versus 600 dpi for retransfer printing. Also, because the ribbon is applied directly to the card, it leaves a thin white border around the edges rather than true edge-to-edge coverage. The printed layer is also more susceptible to scratching and rubbing than a laminated retransfer card, though a lamination module can help close that gap. Direct-to-card works best on smooth, standard PVC cards and is less effective on textured or non-standard card body materials. 

ABCorp’s instant issuance solution supports direct-to-card printing on preprinted cards, personalizing both the front and back, with a multi-feed option for branches issuing several card designs. For programs prioritizing speed and cost control over specialty finishes, direct-to-card printing is a dependable option. 

The critical role of central card manufacturing in instant issuance 

Central manufacturing plays an important role for financial institutions offering instant card issuance programs.  

The blank white payment cards used in retransfer and direct-to-card printers need to arrive at the branches with print-ready construction and working technology for dual interface payment cards. For direct-to-card printers using preprinted card stock, central manufacturing creates high-quality cards that can then be personalized at branch locations. This preprinted stock can be printed using lithographic (offset) or digital printing techniques depending on card program’s volume, lead time requirements, budget, and design complexity. In addition, central manufacturing and émission centrale can be a more economical route for large initial card portfolios, bulk replacement cycles due to expiration dates or reissues, or specialty card designs. 

Finding the best printing method for your instant issuance card program 

Which printing option is best for your instant payment card program? It all comes down to organizational priorities and the experience you want to create for cardholders.   

If you’re looking for the flexibility to print a large library of cards and deliver them on the spot, retransfer printing is likely the stronger fit. It allows your program to print a wide variety of high-end, durable payment cards. When speed, ease of use, and lower upfront investment are necessary, direct-to-card printing might be the better option.  

No matter which option you choose, don’t overlook the role of central manufacturing in a successful instant issuance program. Be sure to work with a partner that can supply the card stock needed to make your instant issuance a smashing success. Also consider that many financial institutions use more than one method for issuing cards. A credit union might rely on central manufacturing and central issuance for new accounts, while equipping branches with in-branch instant issuance printers when time is of the essence, such as when cards are lost or stolen.  

Retransfer printing vs. direct-to-card printing: a comparison table 

The instant issuance printing decision is a brand decision 

It’s easy to treat instant issuance card printing as a back-office equipment choice, but every card that leaves a branch is a physical extension of your financial institution’s brand. Debit cards and credit cards are handled daily, tapped at terminals, and pulled out of wallets in front of merchants and friends. A card that looks sharp and holds up over time reinforces the same trust that your staff works so hard to create during in-person interactions. 

ABCorp’s approach to payment card issuance is built around our clients’ unique needs and organizational goals. Whether it’s retransfer and direct-to-card printing for instant issuance, or bespoke lithographic printing and finishes for central card stock manufacturing at scale, our team is dedicated to identifying the solutions that best fit the needs of your financial institution. If you’re weighing your options for instant card issuance options or reconsidering the program you already have, we welcome the opportunity to discuss your needs.