Methods of making a core layer for an information carrying card, and resulting products

A method for forming a core layer of a plurality of information carrying card, comprising:

• forming a first thermoplastic layer being monolithic and defining a plurality of cavities, each cavity having a continuous surface profile defined by and being inside the first thermoplastic layer, the continuous surface profile including a bottom wall surface and a sidewall surface in a same surface profile, the first thermoplastic layer comprising at least one thermoplastic material;
• disposing a plurality of inlay layers onto the first thermoplastic layer, wherein at least one portion of each inlay layer is disposed into each respective cavity of the plurality of cavities;
• dispensing a crosslinkable polymer composition into each of the plurality of cavities so as to contact one portion of each inlay layer to form a sandwich structure comprising the first thermoplastic layer, each inlay layer and the crosslinkable polymer composition;
• and
• curing the crosslinkable polymer composition under pressure and heat to form a crosslinked polymer composition, wherein curing the crosslinkable polymer composition under the pressure comprises pressing the sandwich structure between two metal plates spaced by a metal frame having a controlled thickness.