0.08mm–0.10mm Clear PC Coated Overlay Film for Card Lamination
Wallis clear polycarbonate coated overlay film is supplied in 0.08mm and 0.10mm thicknesses for professional card lamination. The transparent PC layer protects printed graphics and supports durable multi-layer constructions for identity cards, access credentials, smart cards, driver licences, passport data pages and other secure card projects.
Buyers can specify coated, strong-coated, non-coated or laserable PC grades according to the printed layer, card-body material, lamination equipment and personalization process. Sheet size, surface texture, coating side, cutting format and packaging can be developed for OEM card factories and security-document converters.
Clear PC Coated Overlay Film Specifications
The following values summarize the product options shown on the current page. Final thickness tolerance, coating construction, texture, optical performance and lamination window should be confirmed in the approved technical data sheet, quotation and production sample.
| Parameter | Available Specification | B2B Confirmation Point |
| Base Material | Transparent polycarbonate (PC) | Confirm resin grade and whether the project requires standard, laser-reactive or specialty security film. |
| Standard Thickness | 0.08mm / 80μm and 0.10mm / 100μm | Confirm nominal thickness, permitted tolerance and total finished-card construction. |
| Format | A4, A3 and custom-cut sheets | Provide sheet dimensions, grain or machine direction, squareness and registration requirements. |
| Overlay Grade | Coated, strong-coated, non-coated and laserable options | The correct grade depends on the adjacent printed layer, ink system, card-body material and laser-personalization design. |
| Surface | Clear, glossy, matte, frosted or specified texture | Approve gloss, haze, texture direction and visual effect with a physical sample. |
| Coating Side | Single-side or project-specific bonding treatment | Clearly identify the lamination side and printed side in artwork, packaging and operating instructions. |
| Magnetic Stripe Option | LoCo or HiCo magnetic configurations may be quoted separately | Confirm coercivity, stripe width, position, orientation and encoder compatibility. Magnetic grades are separate constructions. |
| Supply Form | Cut sheets; other converting options subject to review | Confirm protective film, interleaving, sheet count, carton labels and pallet requirements. |
What Is a Polycarbonate Coated Overlay?
A PC coated overlay is the transparent outer layer used above a printed card layer during heat-and-pressure lamination. The polycarbonate base supplies optical clarity, toughness and dimensional stability, while the prepared bonding surface is selected to improve interlayer adhesion in the intended card construction.
The overlay is not the complete card and does not create security by itself. Its performance depends on the PC core or printed inlay, ink and coating chemistry, embedded chip or antenna, lamination cycle, cooling pressure, cutting process and final personalization method.
Coated PC Overlay
A coated grade is selected when the adjacent printed or specialty layer requires a prepared bonding interface. The coating side must face the approved printed layer, and peel strength should be measured after the complete card has been laminated and conditioned.
Strong-Coated PC Overlay
Strong-coated film is intended for more demanding bonding conditions, such as heavy ink coverage, specialty print layers or hybrid constructions. It should not be selected solely from the product name; the ink system, substrate and lamination parameters must be evaluated together.
Non-Coated PC Overlay
Non-coated transparent PC film may be used in compatible all-PC structures where the selected films bond directly under controlled heat and pressure. Its suitability must be confirmed with the exact film grades and document construction.
Laserable PC Overlay
Laserable overlay contains a laser-responsive formulation designed for high-contrast personalization within the card body. A standard clear coated overlay must not be assumed to be laserable. Buyers should specify laser wavelength, personalization depth, image contrast, clear-window design and security requirements.
![0.08mm clear polycarbonate coated overlay film for secure card lamination]( "0.08mm Clear PC Coated Overlay Film")
0.08mm Clear PC Overlay
![0.10mm clear polycarbonate coated overlay sheet for ID card production]( "0.10mm Clear PC Coated Overlay Film")
0.10mm Clear PC Overlay
0.08mm vs 0.10mm PC Overlay: How to Select
| Selection Factor | 0.08mm / 80μm | 0.10mm / 100μm |
| Typical Design Role | Thinner protective layer where the total card stack has limited thickness allowance. | Thicker outer layer where additional material contribution or a more robust surface is required. |
| Card Stack | Useful for multi-layer structures containing several print, security or electronic layers. | Useful when the core structure is thinner or the design allocates more thickness to the overlay. |
| Processing Review | Check handling, static control, sheet feeding, registration and risk of curl. | Check heating time, cooling pressure, punching load and final card stiffness. |
| Final Decision | Select thickness from the complete card drawing, not from the overlay alone. Validate total thickness, lamination, flatness, bending, torsion, edge quality and personalization after production. |
PC Overlay Grade Selection for B2B Card Projects
| Project Requirement | Recommended Grade to Evaluate | Required Validation |
| Transparent protection over a compatible PC printed layer | Non-coated or standard coated clear PC overlay | Optical clarity, print interaction, lamination bond and surface texture. |
| Heavy ink coverage or difficult printed interface | Strong-coated clear PC overlay | Ink curing, coating compatibility, peel strength and edge delamination after conditioning. |
| Laser-personalized secure ID document | Laserable PC overlay or designed laserable layer | Laser wavelength, contrast, resolution, depth, ghost image and clear-window performance. |
| Matte or tactile credential surface | Specified matte, fine-matte, velvet or frosted texture | Gloss, haze, readability, tactile appearance and abrasion after lamination. |
| Magnetic stripe card | Dedicated PC magnetic stripe overlay | Coercivity, stripe placement, encoding, surface step, adhesion and abrasion. |
| PC overlay bonded to PVC, PETG, adhesive or specialty layer | Project-specific coated or adhesive-compatible grade | Hybrid-material thermal expansion, bond strength, curl, cracking and accelerated aging. |
PC vs PVC vs PETG Overlay Film
Overlay materials should be selected as part of the complete card system. Substituting one polymer for another without adjusting the core, coating and lamination cycle can cause weak bonding, curl, haze or cracking.
| Material | Common Strength | Typical Project Fit | Main Qualification Point |
| PC | Toughness, heat resistance, dimensional stability and compatibility with high-security PC card constructions. | Government ID, driver licence, passport data page, secure credential and durable e-card projects. | Confirm laserability, texture, internal stress, coating and complete PC-layer bond. |
| PVC | Cost-effective processing and broad use in conventional plastic-card production. | Membership, gift, access, hotel and standard commercial cards. | Confirm Vicat, coating, ink compatibility and card durability requirements. |
| PETG | Clear appearance and useful bonding characteristics in compatible PETG card structures. | PETG-based cards, selected sustainable-material programs and specialty transparent designs. | Confirm overlay/core compatibility, shrinkage, lamination window and cutting behavior. |
Printing, Lamination and Laser Personalization Compatibility
Printing Is Normally Performed on the Internal Card Layer
In most card structures, graphics are printed on a white or transparent internal PC layer and then protected by the clear overlay. Direct printing on the external overlay requires a separately approved printable surface. Do not assume that a bonding coating is also a printing coating.
Full-PC Mono-Block Construction
Compatible PC layers can form a highly integrated card body under controlled temperature and pressure. The supplier's coating recommendation, film orientation, pre-drying requirements, lamination cycle and cooling procedure should be followed. The finished document should be tested rather than relying on raw-film properties alone.
Hybrid Card Construction
When PC is combined with PVC, PETG, adhesive films, printed coatings or electronic inlays, differences in softening behavior and thermal expansion may affect bonding and flatness. A project-specific coated grade and pilot lamination are required.
Laser Engraving Requires a Laser-Reactive Grade
Standard clear PC overlay provides protection but may not produce the required laser contrast. For laser-personalized ID documents, specify whether text, portrait, tactile engraving, transparent-window image or multiple laser image functionality is required, then test the proposed laserable layer with the intended equipment.
![matte clear polycarbonate overlay film for secure card lamination]( "Matte Clear PC Overlay Film")
Matte PC Overlay Surface
![frosted polycarbonate overlay film for customized card surface texture]( "Frosted PC Overlay Film")
Frosted PC Overlay Surface
Applications of 0.08mm–0.10mm Clear PC Overlay Film
National and regional ID cards: transparent protection and secure multi-layer PC construction, subject to issuer specifications.
Driver licences: durable printed-data protection and optional laser-personalization layers.
Passport data pages: PC overlay components for qualified high-security document structures.
Electronic ID and access credentials: protection of printed layers around compatible chip and antenna constructions.
Healthcare and insurance cards: long-life credentials requiring clear graphics and controlled lamination.
Banking and payment-card development: material evaluation for projects governed by the issuer, card scheme and applicable technical standards.
Industrial graphic overlays: selected labels or panels where the exact coating, printing and environmental requirements have been qualified.
![multi-layer identity card structure using clear polycarbonate coated overlay film]( "Polycarbonate Card Layer Structure")
Recommended PC Card Development Workflow
| Step | Buyer Input | Technical Output |
| 1. Structure Review | Layer drawing, final card thickness, core material, chip/inlay and security features. | Preliminary overlay thickness, grade, coating and surface recommendation. |
| 2. Printing Review | Printing process, ink brand, curing method, coverage and personalization technology. | Coating-side orientation and compatibility test plan. |
| 3. Sample Supply | Sheet size, quantity and test format. | Representative material samples with identification and handling instructions. |
| 4. Pilot Lamination | Actual printed layers, equipment, plates, temperature, pressure, dwell and cooling cycle. | Pilot sheets or cards for bond, optical and dimensional evaluation. |
| 5. Golden Sample | Approved appearance, laser result, peel strength and finished-card tests. | Signed physical reference and agreed specification for bulk production. |
| 6. Batch Control | Inspection level, test method and traceability requirements. | Batch records, labels and agreed inspection report where contracted. |
Quality Control and Batch Acceptance
Acceptance limits should be agreed before ordering. Test methods and values may differ by security-document program, so the following items are a practical qualification framework rather than universal specifications.
| Inspection Item | What to Check | Recommended Stage |
| Thickness and Size | Nominal thickness, variation, sheet dimensions, squareness and edge condition. | Incoming raw material and each production batch. |
| Optical Appearance | Transparency, haze, gloss, texture, contamination, gels, scratches and coating streaks. | Incoming inspection and after lamination. |
| Coating Identification | Correct coated side, coating uniformity, lot marking and packaging orientation. | Before printing or lamination. |
| Lamination Bond | Peel strength, edge separation, bubbles, silvering and delamination after conditioning. | Pilot cards and routine finished-card sampling. |
| Dimensional Stability | Curl, shrinkage, distortion, card flatness and registration after heating and cooling. | After pilot lamination and whenever the cycle changes. |
| Surface Durability | Abrasion, scratch, chemical exposure and cleaning resistance using the project test method. | Finished-card qualification. |
| Laser Performance | Contrast, resolution, grayscale, depth, tactile feature and window-image quality for laserable grades. | Golden Sample and batch verification where required. |
| Electronic Function | Chip response, contactless read distance and antenna continuity before and after lamination. | Pilot and finished smart-card testing. |
Packaging, Storage and Global Shipping
Clear overlay surfaces should be protected from dust, scratches, moisture and incorrect stacking. Packaging may include protective film or interleaving, moisture-resistant wrapping, cartons, pallets and custom labels. Store unopened material flat in a clean, dry environment away from direct sunlight, heat sources and aggressive chemicals.
Before use, allow packaged sheets to reach the production-room condition and follow the agreed handling or pre-drying procedure. Do not remove protective packaging earlier than necessary, and keep the coating-side identification with each partial pack.
![moisture-resistant export pallet packaging for PC overlay sheets]( "PC Overlay Export Pallet Packaging")
Protected Pallet Packaging
![secure export packaging for clear polycarbonate overlay lamination film]( "Polycarbonate Overlay Export Crate")
Secure Export Packaging
Why Source Clear PC Overlay Film from Wallis?
Wallis supports card factories, security printers, converters and material distributors with PC core films, clear overlays, coated overlays, laserable films, magnetic stripe overlays and related card materials. The practical advantage is the ability to review the complete card stack instead of quoting an isolated transparent sheet.
0.08mm and 0.10mm clear PC overlay options for card-production evaluation.
Coated, strong-coated, non-coated, laserable and specialty constructions subject to project review.
Custom sheet cutting, surface texture, coating orientation, labels and export packaging.
Material samples for printing, lamination, laser and finished-card validation.
Support for full-PC and qualified hybrid card structures.
Batch specification and Golden Sample control for repeat OEM orders.
![Wallis technical and export team for polycarbonate card overlay projects]( "Wallis Card Material Team")
Technical and Export Team
![global B2B customers for PC overlay and plastic card materials]( "Wallis Global Card Material Customers")
Global B2B Projects
![Wallis factory for polycarbonate overlay film and secure card materials]( "Wallis Polycarbonate Film Factory")
Card Material Production
Information Required for a Fast B2B Quotation
| Required Information | Example Details to Provide |
| Application | National ID, driver licence, passport data page, access card, e-card, banking evaluation or industrial overlay. |
| Card Structure | Full layer drawing, each material and thickness, final card thickness, clear window and embedded electronics. |
| Overlay Requirement | 0.08mm or 0.10mm, coated/non-coated/strong-coated/laserable, surface texture and coating side. |
| Printing and Ink | Offset, screen, digital or security printing; ink brand, curing system and ink coverage. |
| Lamination Process | Equipment, plate type, temperature, pressure, dwell time, cooling pressure and current defect description. |
| Personalization | Laser model and wavelength, contrast requirement, tactile feature, clear-window image or non-laser personalization. |
| Sheet and Packaging | Width × length, quantity, pack count, protective film, carton label and pallet requirements. |
| Quality Documents | TDS, SDS, inspection report, traceability, regulatory declarations or issuer-specific documents. |
Frequently Asked Questions
What is 0.08mm–0.10mm clear PC coated overlay film used for?
It is used as a transparent outer layer in laminated polycarbonate card and security-document structures. It protects printed information and can contribute to the mechanical integrity of ID cards, driver licences, e-cards and other qualified credentials.
What is the difference between coated and non-coated PC overlay?
Coated overlay has a prepared bonding surface intended to improve adhesion to the approved adjacent layer. Non-coated PC film may be suitable for compatible all-PC structures. The correct choice depends on the printed layer, ink, film grade and lamination cycle.
Is standard coated PC overlay laserable?
Not necessarily. Laser engraving requires a laser-responsive grade designed for the intended wavelength and contrast. Specify laser requirements before sampling rather than assuming that every transparent PC overlay can be personalized by laser.
Should I choose 0.08mm or 0.10mm overlay?
Choose from the complete card-layer drawing and final thickness target. The 0.08mm grade leaves more thickness for internal layers, while 0.10mm contributes more material to the outer structure. Both require finished-card testing.
Can the PC overlay be laminated to PVC or PETG?
A hybrid construction may be possible with a suitable coating or bonding layer, but it must be tested because PC, PVC and PETG have different thermal and dimensional behavior. Do not apply an all-PC lamination cycle to a hybrid card without qualification.
Can I print directly on the clear PC overlay?
Direct printing requires a separately approved printable surface. In many card structures, printing is performed on the internal core or print layer and the clear overlay is laminated above it. A bonding coating is not automatically a printing coating.
Which surface textures are available?
Clear glossy, matte, fine-matte, frosted or other project-specific textures may be evaluated. Texture availability and exact gloss or haze should be confirmed with a physical sample and quotation.
Does PC overlay make a card tamper-proof?
No single overlay can guarantee that. Compatible PC layers can form a strongly integrated structure, but security depends on the complete document design, controlled materials, laser personalization, chips, security printing, issuance and verification system.
Can magnetic stripes be supplied on PC overlay?
Dedicated magnetic stripe overlay constructions may be quoted. Confirm LoCo or HiCo coercivity, stripe width, position, orientation, surface step and compatibility with the intended encoder and card standard.
What tests should be completed before bulk production?
Test printing interaction, lamination bond, curl, optical clarity, surface texture, cutting, bending, torsion, abrasion, chemical exposure, laser personalization and electronic function where applicable. Approve a Golden Sample before bulk supply.
Can Wallis provide custom sheet sizes and packaging?
Yes. A4, A3 and custom-cut sheets can be reviewed together with protective film, interleaving, pack quantity, labels, cartons and pallet requirements. Final options depend on the selected film grade and order specification.
What information is needed to request samples?
Provide the card application, full layer structure, overlay thickness, coated or laserable requirement, sheet size, printing process, ink, lamination cycle, laser system and required tests. This allows a more relevant sample to be selected.
