Unsure of the difference between direct-to-card (or dye sublimation) and retransfer printing? It’s all in the process of transferring the image onto the PVC card and whether it’s printed directly to the card surface or via a thin, clear substrate first. But what are the advantages of using one technology versus the other?
DTC vs retransfer
Direct-to-card
A direct-to-card (DTC or dye sublimation) printer prints ink directly onto a card’s surface. This kind of printer uses dye film which feeds in between two spools in the printer and, when it comes into contact with the thermal printhead, the card design will be printed onto the card.
Our dye film ribbons are arranged in panels for each colour and the overlay, as per the image on the right.
The most popular choice, DTC printers tend to be:
- faster
- have a smaller footprint
- cheaper to purchase
- simpler to use
- lower cost per card
- one consumable cost
Retransfer
Retransfer (reverse transfer) printing technology uses a two-step process by first printing the colour images onto a thin clear substrate, then heat transferring this substrate, complete with the printed CMYK image, onto the surface of a card.
These types of printers produce cards that are:
- durable
- more secure
- more expensive
- printed “over-the-edge”
Other considerations
Let’s take a look at some of these elements in more detail:
Speed
Direct-to-card printers produce ID cards faster than retransfer printers so they’re suited to those with higher print volume requirements. Most high-volume direct-to-card printers allow you to produce a single-sided colour card in just a few seconds.
Longevity and print consistency
While cards printed using a DTC printer have a good lifespan, the retransfer process inherently improves card durability. As the colour is printed onto the underside of the retransfer film, the image is protected from direct contact with ID card holders, wallets, magnetic stripe or contact chip machines. The card keeps its original colour and quality much longer than most direct-to-card prints.
The printhead used in a retransfer printer never touches the surface of the card, making it less likely to be damaged or to malfunction. It isn’t exposed to any dust and dirt which may be on the card surface or uneven/poorly constructed PVC cards which can sometimes lead to poor results. Because the retransfer film that is being printed onto is a known and controlled substrate, print quality is more consistent than direct-to-card technology where the variable surface of the PVC card or slightly raised areas such as an embedded contact chip can all impact on print performance.
Print coverage
Retransfer technology uses a slightly larger film to use as a bleed margin extending beyond the edge of the card, so when it is transferred to the card’s surface it leaves no white margin whatsoever. This can be useful depending on branding requirements. It’s also a way to be able to visually detect tampering.
Direct-to-card technology prints “edge to edge”, inherently leaving a (almost imperceptible) white margin.
Security
Whichever method you use, with Magicard you can apply a secure watermark to each card during the retransfer process. This feature exploits the wavelengths and lens effect to fluoresce under UV lighting conditions. See HoloKote
Retransfer printers can be combined with an inline laminator to enable the addition of an overlay to the card surface. This further protects the card from wear and fading of the image, mainly for cards which are used frequently or in outdoor environments. Laminates can be overlays or patch. Patch provides a thick protection layer on the card but is not quite edge-to-edge. Overlay provides a thinner protection layer but is fully edge-to-edge. Both types of laminates can also be supplied with a customisable holographic security design. This is particularly suited to very high volume secure card printing.
Conclusion
Ultimately, it all depends on what you’re looking for. Do you need high speed, high volume ID card printing capability or are you looking for something with additional durability and security? Take a look at our range of options for DTC and retransfer printing.
