Abstract: A card substrate laminating device including a transfer roller configured to heat a portion of a transfer layer of a transfer ribbon and transfer the portion of the transfer layer from a carrier layer of the transfer ribbon to a surface of a card substrate. The transfer roller includes a diameter of less than 0.537 inches and a compliant exterior surface layer or coating. The compliant exterior surface layer or coating can include silicon rubber. The compliant exterior surface layer or coating can be approximately 0.020 inches thick. An internal heating element is configured to heat the transfer roller from an ambient temperature to a laminating temperature, at which laminating operations are performed, within 40 seconds.

Abstract: A card substrate laminating device including a transfer roller configured to heat a portion of a transfer layer of a transfer ribbon and transfer the portion of the transfer layer from a carrier layer of the transfer ribbon to a surface of a card substrate. The transfer roller includes a diameter of less than 0.537 inches and a compliant exterior surface layer or coating. The compliant exterior surface layer or coating can include silicon rubber. The compliant exterior surface layer or coating can be approximately 0.020 inches thick. An internal heating element is configured to heat the transfer roller from an ambient temperature to a laminating temperature, at which laminating operations are performed, within 40 seconds.

Abstract: A card substrate laminating device includes a transfer ribbon and a transfer roller. The transfer ribbon includes a carrier layer and a transfer layer attached to the carrier layer. The transfer roller is configured to heat and transfer a portion of the transfer layer from the carrier layer to a surface of a card substrate. The transfer roller has a circumference that is less than one-half of a length of the card substrate.

Abstract: A card substrate laminating device includes a transfer ribbon and a transfer roller. The transfer ribbon includes a carrier layer and a transfer layer attached to the carrier layer. The transfer roller is configured to heat and transfer a portion of the transfer layer from the carrier layer to a surface of a card substrate. The transfer roller has a circumference that is less than one-half of a length of the card substrate.

Abstract: A printer includes a print ribbon, a transfer ribbon, a printhead, and a first sensor. The transfer ribbon includes a series of panels each separated from adjacent panels by a transition portion. A section of the transfer ribbon is supported between a supply roll and a take-up roll and has a feeding direction that is toward the take-up roll. The printhead is configured to transfer print material from the print ribbon to the section of transfer ribbon. The first sensor is positioned downstream of the printhead relative to the feeding direction of the section of transfer ribbon and includes an output signal that is indicative of a position of one of the transition portions relative to the printhead.

Abstract: Methods and systems are described for forming identification cards. The methods and systems incorporate a patch laminate transport for transporting a patch laminate along a patch laminate path and a card transport for transporting a card substrate along a card path. The patch laminate path and card path are substantially perpendicular to each other and intersect at an intersecting junction. A middle portion of the patch laminate is aligned with the intersecting junction. An intersecting edge of the card substrate is driven into the middle portion. A lamination mechanism laminates a first laminate portion to a first face and a second laminate portion to a second face of the card substrate.

Abstract: Methods of the present invention relating to an identification card printer include a method of calibrating a ribbon sensor for detecting transition portions between adjoining panels of a ribbon and a method of calibrating tension in a ribbon. Identification card printers in accordance with embodiments of the invention include a sensor positioned downstream of a printhead relative to a feeding direction of a ribbon; support for a printhead that is moveable between print and withdrawn positions; a swing frame supporting a first roll of a ribbon for rotation about an axis about which the swing frame pivots; an adjustable card guide in line with a print path; and a card bender including a pinch roller assembly having first and second rollers, axes of rotation of which are aligned in a plane that is non-perpendicular to a card path.