Automated Card Finishing: Cutting, Milling and Notching Tolerances That Matter
Automated Card Finishing: Cutting, Milling and Notching Tolerances That Matter
Published: 2026-08-24
Card finishing turns laminated sheets into ISO-sized cards ready for modules and printing. Small tolerance errors cascade into jammed encoders and failed mechanical tests. This article covers the tolerances that separate a reliable finishing line from a troublesome one.
Cutting Accuracy
High-speed rotary and flat-bed die cutters should hold the card edge within +/- 0.05 mm of the ISO 7810 85.60 x 53.98 mm nominal. Edge burr below 0.02 mm prevents reader-feed jams. Register between the printed image and the cut must stay under 0.10 mm across the sheet.
An automatic punching machine holding tight cutting tolerances on finished cards.
Milling and Notching
Cavity depth
Module pocket depth held to +/- 0.03 mm so the module sits flush after lamination.
Notch position
Mag-stripe notch and keyhole located within +/- 0.08 mm for consistent post-processing.
Reference Tolerance Table
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