The Birth of a Card Sleeve

Some people think a clear card holder is “just two sheets of plastic pressed together.” By the time you finish this, you’ll know — the wrong film turns yellow, two degrees off and the seam splits, and static can scrap half your batch. We’ll break it down, plain and simple.

1：Material First — Wrong Film, Everything Else Falls Apart
Transparent PVC Film：Soft, high clarity, heat-sealable, cost-effective，Bank cards, membership cards, postcards，The go-to choice.

PET Film：Rigid, ultra-clear, recyclable, eco-friendly，Business cards, premium gift cards，Best looks, higher cost

Frosted / Matte Film：Semi-transparent, scratch-resistant, textured feel，Privacy cards, VIP card sleeves，Subtle and classy.

Colored / Printed Film：Custom colors and prints, strong branding，Corporate custom, promotional gifts，Biggest markup potential.

Hidden logic on thickness: bank cards are 0.76mm, postcards about 0.3mm. PVC film typically runs 0.15–0.3mm. After heat-sealing two layers, leave at least 1mm of interior clearance — or the card won’t fit, or the corners will burst.

The Process — Six Steps from Film Roll to Finished Sleeve:
Slitting & Cutting:Cut the film roll to finished dimensions. Tolerance: ±1mm. Cut crooked and the seal line shifts.
Printing (if required):Silk-screen or offset print logos and patterns. Ink adhesion must pass testing — or it peels after sealing.
RF Heat Sealing:The critical step. Align two film layers in the mold, then RF-seal with heat and pressure. Temperature, dwell time, and pressure — all three must be right.
Die-Cutting & Trimming:Use a die to punch the final shape and trim excess. Rounded corners or sharp — this is where it’s decided.
Static Removal & Cleaning:Film attracts dust and lint like a magnet. Run each piece past an anti-static bar and wipe with a lint-free cloth.
QC & Packing:Inspect each piece: seal strength, bubbles, wrinkles, clarity. Pass? Into OPP bags they go.

Where Things Go Wrong — And How to Fix Them:
Problem: Seal splits or won’t bond:Temperature too low or pressure uneven. PVC typically seals at 140–170°C — adjust for film thickness. Fix: run a test sample first, lock in the optimal temp + dwell time, and recalibrate with every new film batch.

Problem: Film turns yellow or loses clarity:Two causes: low-grade film (high recycled content) or overheating during sealing. Fix: specify virgin material at purchase, and keep sealing temp 5°C below the degradation threshold.

Problem: Cards too tight to insert, or slip right out:Interior pocket size is off. Standard bank card: 85.6×54mm. Recommended interior: 87×56mm — to allow for film thickness and seal margin. Too tight? Add 1mm. Too loose? Subtract 1mm. Always sample before bulk.

Problem: Static attracts dust, impossible to wipe clean:PVC builds strong static in dry conditions. Fix: keep workshop humidity at 50–60%, pass finished pieces over an anti-static bar, wear anti-static gloves during packing. For volume runs, install an ionizing air nozzle.

Packaging & Shipping — Clear Products Need Extra Care:
Packaging approach:Card sleeves are thin and light — scratch and crease prevention is key:
— Slip each sleeve into an OPP bag
— Stack 50–100 per bundle, with stiff boards top and bottom
— Wrap with bubble wrap or EPE foam
— Pack in 5-ply corrugated cartons, fill all voids
— Custom orders: add printed outer bag or hang card

Shipping checklist:
— No heavy pressure or bending — creases are permanent
— Avoid high heat (truck interiors can fuse layers together)
— Sea freight: add desiccant packs inside cartons
— Mark “DO NOT CRUSH / DO NOT FOLD” on cartons
— Samples: DHL / FedEx, 3–5 days
— Bulk: sea freight ~25–35 days, air ~5–7 days

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