Most cardholders never think about what it takes to put ink on a physical payment card. However, the printing process is a meaningful decision for card program managers across all industries given its impact on manufacturing costs and timelines. The printing process shapes the physical look and feel of finished CR80 cards, the speed at which they can be manufactured and fulfilled, and their overall durability throughout their lifespans both in cardholder’s wallets and interacting with POS devices in the field.
The two primary methods of printing used to manufacture physical payment cards are lithographic printing and digital printing. As with all manufacturing decisions, there are pros and cons to carefully consider with each option. Understanding the strengths and limitations of both can help card program managers work more efficiently with card manufacturers and set appropriate expectations for the finished product.
What is the process for debit card and credit card printing?
Before starting the comparison, it helps to understand what printing a physical payment card actually requires. A payment card isn’t printed the way a paper brochure is, for example. The card body, typically a laminated stack of plastic layers, needs to hold precise color fidelity under heat, pressure, and daily handling. Inks must bond to card substrates without cracking, fading, or flaking over the life of the card. The credit card printing process happens before lamination, personalization with elements including cardholder name and CVV, and EMV chip or antenna embedding, which means any defect in the print layer compounds further down the production line.
With that in mind, the choice of printing method is less about preference and more about what the program requires.
Lithographic printing for payment cards: strengths and limitations
Lithographic printing, also called offset printing, uses a series of plates to transfer ink onto the card substrate. Each color in the design requires its own plate, and the plates are applied in sequence to build up the final image.
What are the strengths of lithographic printing for payment cards?
- Color accuracy and consistency.
Lithographic printing produces exceptional color matching, which matters when a brand’s identity depends on hitting a specific shade across millions of cards. The color output tends to be consistent, is highly repeatable, and can be executed at scale.
- Cost efficiency for high-volume runs.
Once the plates are made, the per-unit cost drops significantly. For large card programs issuing hundreds of thousands of cards, lithographic printing is typically the more economical option.
- Print quality on complex designs.
Fine gradients, metallic effects, and detailed background patterns tend to render more reliably with offset printing, particularly for specialty finishes.
What are the limitations of lithographic printing for credit cards and debit cards?
- Upfront setup costs.
Plate production takes time and adds cost. For shorter runs or programs testing new card designs, that setup investment can be prohibitive.
- Limited flexibility for customization.
If you want variable data, regional card variations, or design changes mid-run, lithographic printing is unlikely the best option. The plates are static and once they are set up, they apply to the whole run and cannot be changed mid-stream.
- Longer lead times.
Prepress work, plate creation, and press setup mean the path from approved artwork to print-ready cards takes longer than digital alternatives. For card programs that receive orders with short notice and need to manufacture cards quickly, offset printing may not be the best option.
Digital printing for payment cards: strengths and limitations
Digital printing applies ink directly to the substrate using inkjet or laser-based systems, with no plates required. The design is sent digitally, and the press prints it directly.
What are the strengths of digital printing for payment cards?
- Speed and flexibility.
Without plates, setup is minimal. Design changes can be made quickly, and short runs become economically viable. For pilot programs, limited-edition cards, or regional variations, digital printing can be a strong choice.
- Personalization and variable data.
Digital presses can print variable elements within a single run, making it easier to produce individualized designs or region-specific card variants at scale.
- Lower barrier for small programs.
Credit unions and community banks with smaller issuance volumes often find digital printing more accessible, with lower minimum order quantities and faster turnaround times.
What are the limitations of digital printing for credit cards and debit cards?
- Color matching at high volumes.
Consistent color reproduction across very large runs can be harder to maintain with digital printing than with lithographic methods. For brands with strict color standards, this barrier may be difficult to overcome.
- Substrate and finish limitations.
Not all specialty materials and finishes are compatible with digital presses. Metallic card bodies, certain textured substrates, and some premium finishes may require offset printing.
- Per-unit cost at scale.
As volumes increase, digital printing’s per-unit cost tends to stay flat or decline slowly, while lithographic printing’s cost curve tends to drop steeply. The economics of digital printing may ultimately not make financial sense for large card programs.
Which printing method is best for manufacturing physical credit cards and debit cards?
| Lithographic Printing | vs. | Digital Printing |
|---|---|---|
| Cost-effective for high-volume printing | Cost | Cost-effective for low-volume printing |
| Reliable for color accuracy and specialty finishes | Quality | Limited color accuracy for higher volumes; not all finishes are compatible |
| Optimal for large card programs | Quantity | Optimal for smaller card programs |
| Static plates prohibit use of variable data | Personalization | Prints variable elements within a single run |
| Limited customization with higher setup costs | Customization | Quickly and easily prints individualized or region-specific designs |
The right method depends on your program’s priorities. A large financial institution rolling out millions of consumer debit cards with a fixed design has different needs than a credit union launching a limited co-branded card or a fintech testing a new card product.
When it comes time to discuss printing techniques with your card manufacturer, enter the conversation prepared with answers to the following questions:
- What is your physical card program’s projected annual issuance volume?
- How frequently does your card program print new designs and/or regional variants?
- Do you have strict brand color standards that require color matching?
- What is your lead time expectation from design approval to card delivery?
The right card solutions partner will work through these questions with you rather than defaulting to a single printing method. The best programs are built on the right combination of capabilities, and it’s imperative to work with a provider that offers choice.
At ABCorp, our physical card manufacturing capabilities include both lithographic and digital printing. We work with card program managers to understand their needs and pick the right option for their volumes, timelines, and design requirements.
