Abstract: A sensor system for counting cards includes an optical sensor assembly configured to detect edges of cards in a card stack. The optical sensor assembly includes at least an optical sensor, and a light element coupled with the optical sensor. The light element is configured to reflect light from a card stack toward the optical sensor. A remote light element is spaced from the optical sensor assembly. The remote light element is configured to direct light toward the card stack.

Abstract: Systems, mechanisms, and methods are described that relate to the production of a custom printed insert(s) that can be custom printed prior to insertion of the custom printed insert(s) into an envelope along with a personalized card/carrier combination for mailing to the intended holder of the personalized card. The inserts are custom printed using an insert printer that is located in the inserter mechanism that is used to insert the insert(s) and the card/carrier combination into an envelope for mailing to an end user of the card. The inserter mechanism can have an “off-line” configuration, i.e. configured as a stand-alone mechanism, or configured for “in-line” use, i.e. used together with other mechanisms.

Abstract: Systems and methods for performing retransfer printing on substrates such as plastic card-shaped substrates. Printing is first performed in at least first and second separate transfer areas on the retransfer film. The retransfer film is then advanced to a retransfer station where the printed transfer areas are transferred to the substrate in a sequence that differs from the sequence in which the printed transfer areas were printed.

Abstract: Systems and methods that utilize a card reorienting mechanism are described. Generally, the card reorienting mechanism can transport and rotate a card without substantially contacting one of the principal surfaces of the card. The use of the card reorienting mechanism permits reorienting of the card without substantially contacting the principal surface of the card after the operation has been performed on the principal surface of the card. The card reorienting mechanism of the present disclosure can be useful where rotation of the card without contacting the principal surfaces of the card is desired moments after ink is applied to one of the principal surfaces of the card. In addition, substantially the entire principle surface is accessible for processing operations while the card is on the reorienting mechanism, such as for laser personalization or for image capture.

Abstract: A label printer mechanism that is configured to produce and affix custom printed customer engagement labels to personalized plastic cards and other substrates. The custom printed customer engagement labels can be used for a number of purposes including, but not limited to, instructions to the intended recipients of personalized plastic cards for activation of the personalized plastic cards, marketing of products and/or services to the recipients, and combinations of activation and marketing.

Abstract: A remote user interface (RUI) for a personalization document printer of an instant issuance system is provided. The RUI includes a printer functionality component and a server functionality component. The server functionality component is configured to allow, for example a user to control user authentication to use the printer, control print queues of the printer, control print workflows of the printer, control RUI configuration, control remote access to printer user functions and a print preview displaying an image of the customized personalization document with image data and personalization account data, control storage and rendering of data to be placed on a customized personalization document, lock and unlock access to supplies and/or personalization documents in the personalization document printer, access administrative functions, and provide quality assurance functions.

Abstract: A system and method for remote monitoring and management of an instant issuance system is provided. The embodiments provide secure communication between different entities within the instant issuance system. Security can be established via mutual authentication between the communicating entities of the instant issuance system prior and/or concurrent with a communication taking place.

Abstract: Modular print engines and print engine components that are usable in desktop card printers for personalizing plastic cards such as financial cards including credit and debit cards, identification cards, driver's licenses, and other personalized plastic cards. The modular nature of the print engines and print engine components permit alteration in the specific functionality of the desktop card printers depending upon, for example, the personalization requirements of the plastic cards and intended applications of the desktop card printers. In addition, the modular print engine components can be completely tested prior to installation into the modular print engines to ensure that the modular print engine components are working correctly prior to installation. Furthermore, the modular print engine components add flexibility to the desktop card printers as upgraded functionality and features can be introduced by developing new modular components.

Abstract: Card processing mechanisms and methods whereby after a card has been processed on one surface thereof at a card processing station such as, but not limited to, a card printing mechanism, the card can be recirculated back upstream of the card processing station along a return card travel path that is separate from the primary card travel path through the card processing station where the card can then be reintroduced back into the primary card travel path and transported through the card processing station a second time. As the card is being returned along the return card travel path, the card can be flipped over so that when the card is transported back through the card processing station, the opposite surface of the card can be processed.

Abstract: A method and system for programming a smart card using multiple programming protocols in a single card programming station. The card can include at least two programmable chips, with each chip being programmed using a different programming protocol. Alternatively, the card can include a single programmable chip, and the chip is programmed using at least two programming protocols. The card can also include at least two programmable chips, with each chip being programmed using at least two programming protocols.

Abstract: A ribbon supply includes a supply spool and a ribbon material wound onto the supply spool. A tack down bond prevents unwinding of the ribbon material from the supply spool. A leader film extends from the tack down bond, with the leader film having a length that is sufficient to allow installation of the ribbon supply and connection of the leader film to a take-up spool without detaching the tack down bond.

Abstract: A technique is described by which a warped security feature is created on a substrate using a hybrid vector/bitmap process. The print element follows a series of curved vector lines during printing to form the security feature, instead of the straight line-by-line process used with a bitmap image. The method of producing the warped security feature, the warped security feature, and the substrate containing the warped security feature are considered to be unique and inventive.

Abstract: A plastic card is printed on by transferring an adhesive to a surface of the plastic card from a thermal transfer ribbon using a thermal printhead. A donor material is then applied over the transferred adhesive to adhere the donor material to the card surface with portions of the card surface not containing the transferred adhesive not being covered by the donor material. The techniques described herein permit the addition of high value features, such as three dimensional features, matte finishes, metallic or metallic appearing features, optical structures, and the like, to the surfaces of plastic cards. In addition, the techniques described herein can be integrated into existing card processing systems, such as central issuance card processing systems, that use thermal printing technology.

Abstract: A barrier film, a document including a barrier coating, and a method for producing a document are described. A document includes a substrate, printed data on a surface of the substrate, and a barrier coating. The barrier coating is disposed between a portion of the printed data and a portion of an adhesive. The portion of the adhesive is disposed between a portion of a protective layer and a portion of the substrate.

Abstract: A security document created by laminating a metalized foil between transparent layers, and modifying the outside of the foil to form a base color of the document, while leaving a window area formed by an unmodified portion of the foil. A laser is then used to ablate at least a portion of the unmodified portion of the foil in the window area to create an image. The window area includes the laser ablated image formed therein. The resulting image is transparent, with the image being visible from a front of the security document and visible from a rear of the security document.

Abstract: A security document and method of manufacturing the security document are disclosed. The security document includes a substrate including a laser reactive material and data. The security document also includes an optically variable tactile security feature formed in the laser reactive material, the optically variable tactile security feature including a non-tactile portion and a tactile portion. When viewed at a first viewing angle, the optically variable tactile security feature appears to be a first color, and at a second viewing angle different from the first viewing angle, the optically variable tactile security feature appears to be a second color.

Abstract: Processes and systems are described that can produce images including both three dimensional holographic images and two dimensional variable data, which can provide personalized security features in a document. A photosensitive film can be pressed against a first reflective optical device. A laser beam can be directed through a selected first area of the photosensitive film onto the first reflective optical device to produce a three dimensional holographic image in the photosensitive film. A previously masked second area of the photosensitive film can be pressed against a second reflective optical device. The laser beam can project an image constructed by a spatial light modulator and can be directed through the second area of the photosensitive film onto the second reflective optical device to produce a two dimensional image in the second area. During the process, the web tension of the photosensitive film is controlled.

Abstract: Card processing mechanisms and methods whereby after a card has been processed on one surface thereof at a card processing station such as, but not limited to, a card printing mechanism, the card can be recirculated back upstream of the card processing station along a return card travel path that is separate from the primary card travel path through the card processing station where the card can then be reintroduced back into the primary card travel path and transported through the card processing station a second time. As the card is being returned along the return card travel path, the card can be flipped over so that when the card is transported back through the card processing station, the opposite surface of the card can be processed.

Abstract: Techniques are described for printing on front and back surfaces of security document substrates in a manner that conserves use of print ribbon, thereby extending the life of the print ribbon. In general, the printer controller knows the content, as well as locations and colors, of what has been printed on the front or first surface of the security document substrate. The printer control also knows the content, as well as locations and colors, of what is to be printed on the back or second surface of the security document substrate. When the back surface of the substrate is to be printed, the printer controller determines, for a particular color, whether any of the printing on the back surface would overlap with the printing on the front surface. For locations where there would be no overlap, the printer can reuse the section of print ribbon that was used to print on the front surface to print on the back surface.