Abstract: A drop-on-demand plastic card printer includes a tray disposed underneath the plastic card during drop-on-demand printing to catch any overspray that may occur during printing on the plastic card. The tray may be disposable so that the tray is intended to be removed and disposed of. An ink absorbent pad can be disposed in the tray to absorb the oversprayed ink. The ink absorbent pad can be disposed of along with the tray or disposed of separately from the tray.

Abstract: A DOD print station has at least one DOD print head that applies radiation curable material, to a surface of an identification document. A curing station is adjacent to the DOD print station. The curing station includes at least one radiation emitting device, for example a UV light emitting device, that cures the radiation curable material applied to the surface. The curing station is configured to prevent stray radiation emitted from the radiation emitting device from impinging on the DOD print head(s) and prevent exposure to the operator of the DOD print station.

Abstract: An ink bottle is mounted in a DOD printer with the ink bottle acting as an ink supply reservoir that supplies ink to a DOD print head. A unique cap is provided that is configured to be affixed to an end of the ink bottle via threads or the like. The cap can be provided with one or more mechanical keying features used to limit mounting of the cap and the bottle assembly to a correct receiver in the DOD printer. The cap can also be provided with a valve controlled ink passage that allows ink to flow out of the bottle through the cap and a valve controlled vent passage that allows air to enter the bottle through the cap.

Abstract: A drop-on-demand plastic card printer includes a tray disposed underneath the plastic card during drop-on-demand printing to catch any overspray that may occur during printing on the plastic card. The tray may be disposable so that the tray is intended to be removed and disposed of. An ink absorbent pad can be disposed in the tray to absorb the oversprayed ink. The ink absorbent pad can be disposed of along with the tray or disposed of separately from the tray.

Abstract: A DOD print station has at least one DOD print head that applies radiation curable material, to a surface of an identification document. A curing station is adjacent to the DOD print station. The curing station includes at least one radiation emitting device, for example a UV light emitting device, that cures the radiation curable material applied to the surface. The curing station is configured to prevent stray radiation emitted from the radiation emitting device from impinging on the DOD print head(s) and prevent exposure to the operator of the DOD print station.

Abstract: Techniques are described for reducing or eliminating a bow in a plastic card that results from applying radiation, such as UV radiation, to a surface of the plastic card to cure radiation curable material that has been applied to the surface. In one embodiment, after printing of all radiation curable material on the plastic card is completed, radiation is applied to both surfaces of the plastic card. After applying the radiation, the plastic card complies with ISO 7810:2019, Clause 8.10.

Abstract: A drop-on-demand plastic card printer includes a tray disposed underneath the plastic card during drop-on-demand printing to catch any overspray that may occur during printing on the plastic card. The tray may be disposable so that the tray is intended to be removed and disposed of. An ink absorbent pad can be disposed in the tray to absorb the oversprayed ink. The ink absorbent pad can be disposed of along with the tray or disposed of separately from the tray.

Abstract: A multi-pass drop-on-demand (DOD) card printing mechanism that performs multi-pass DOD printing on a surface of a plastic card whereby the plastic card is transported past one or more DOD print heads multiple times for DOD printing on the card surface with each pass past the DOD print head(s). In a first printing pass, at least one material is applied to a surface of the plastic card using at least one DOD print head. In a second printing pass that occurs after the first printing pass, at least one additional material is applied to the surface of the plastic card in the card processing system using at least one DOD print head.

Abstract: DOD ink delivery systems and methods are described herein that are used in DOD card printing systems of card processing systems for supplying ink for DOD printing on plastic cards of the type that bear personalized data unique to the intended cardholder and/or which bear other card information. The DOD ink delivery system is configured to recirculate the ink, or have a second pressure damper container that provides damping to eliminate large and abrupt spikes in ink pressure which can disturb the meniscus of the ink in each nozzle of the print head generated by a vacuum system, or simultaneously operate a supply pump at a lower flow rate than a return pump during an autofill/autodrain procedure on the ink delivery system.

Abstract: Maintenance routines that can be used to maintain the operability of one or more DOD print heads in a card processing system. The maintenance routines can include, but are not limited to: a cover routine where a cover or cap is selectively and automatically located over the print head(s) to protect the print head(s); a shake pulse routine that energizes the nozzles of the print head(s) without causing an ejection of ink; a spit routine where the nozzles of the print head(s) are energized to eject one or more drops of ink; and a purge routine where the nozzles are not electrically energized but the pressure holding the ink in the nozzles of the print head(s) is reversed to push ink out of the nozzles.

Abstract: An ink bottle is mounted in a DOD printer with the ink bottle acting as an ink supply reservoir that supplies ink to a DOD print head. A unique cap is provided that is configured to be affixed to an end of the ink bottle via threads or the like. The cap can be provided with one or more mechanical keying features used to limit mounting of the cap and the bottle assembly to a correct receiver in the DOD printer. The cap can also be provided with a valve controlled ink passage that allows ink to flow out of the bottle through the cap and a valve controlled vent passage that allows air to enter the bottle through the cap.

Abstract: DOD ink delivery systems and methods are described herein that are used in DOD card printing systems of card processing systems for supplying ink for DOD printing on plastic cards. The ink delivery systems are configured to recirculate the ink without using a recirculation tank separate from an ink supply. The ink can be recirculated back into the ink supply or, when the ink supply is not present, the ink can be recirculated from a return header tank to a supply header tank.

Abstract: An ink bottle is mounted in a DOD printer with the ink bottle acting as an ink supply reservoir that supplies ink to a DOD print head. A unique cap is provided that is configured to be affixed to an end of the ink bottle via threads or the like. The cap can be provided with one or more mechanical keying features used to limit mounting of the cap and the bottle assembly to a correct receiver in the DOD printer. The cap can also be provided with a valve controlled ink passage that allows ink to flow out of the bottle through the cap and a valve controlled vent passage that allows air to enter the bottle through the cap.

Abstract: A drop-on-demand plastic card printer includes a tray disposed underneath the plastic card during drop-on-demand printing to catch any overspray that may occur during printing on the plastic card. The tray may be disposable so that the tray is intended to be removed and disposed of. An ink absorbent pad can be disposed in the tray to absorb the oversprayed ink. The ink absorbent pad can be disposed of along with the tray or disposed of separately from the tray.

Abstract: DOD ink delivery systems and methods are described herein that are used in DOD card printing systems of card processing systems for supplying ink for DOD printing on plastic cards of the type that bear personalized data unique to the intended cardholder and/or which bear other card information. The DOD ink delivery system is configured to recirculate the ink, or have a second pressure damper container that provides damping to eliminate large and abrupt spikes in ink pressure which can disturb the meniscus of the ink in each nozzle of the print head generated by a vacuum system, or simultaneously operate a supply pump at a lower flow rate than a return pump during an autofill/autodrain procedure on the ink delivery system.

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: Maintenance routines that can be used to maintain the operability of one or more DOD print heads in a card processing system. The maintenance routines can include, but are not limited to: a cover routine where a cover or cap is selectively and automatically located over the print head(s) to protect the print head(s); a shake pulse routine that energizes the nozzles of the print head(s) without causing an ejection of ink; a spit routine where the nozzles of the print head(s) are energized to eject one or more drops of ink; and a purge routine where the nozzles are not electrically energized but the pressure holding the ink in the nozzles of the print head(s) is reversed to push ink out of the nozzles.

Abstract: An ink bottle is mounted in a DOD printer with the ink bottle acting as an ink supply reservoir that supplies ink to a DOD print head. A unique cap is provided that is configured to be affixed to an end of the ink bottle via threads or the like. The cap can be provided with one or more mechanical keying features used to limit mounting of the cap and the bottle assembly to a correct receiver in the DOD printer. The cap can also be provided with a valve controlled ink passage that allows ink to flow out of the bottle through the cap and a valve controlled vent passage that allows air to enter the bottle through the cap.

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.