Abstract: A sheet assembly including a sheet of paper or polymer film having a first surface and a second opposed surface, and having a coating material formed on at least the second surface of the sheet. A plurality of parallel substantial-cut lines extend substantially the length and width of a sheet to define two columns of card blanks on the sheet. The substantial-cut lines do not extend substantially into the coating material formed on the second surface of the card assembly. The sheet is passed through a laser or ink jet printer, printing the desired identifying or other indicia on the blanks. The blanks are then separated along the substantial-cut line(s). The cards separate cleanly along the substantial-cut lines, superior to microperforated card separation lines. Even with the substantial-cut line(s), the sheets maintain sufficient integrity to reliably pass through the printer without breaking apart.