Sheet assembly for forming one or more cards

A method comprising:

• forming a polymer core;
• coupling an upper sheet to the polymer core, the upper sheet configured to receive a first printing of first indicia for one or more cards;
• and
• coupling a lower sheet to the polymer core to form a sheet of the upper sheet, the polymer core, and the lower sheet, the lower sheet coupled with the polymer core with the polymer core disposed between the upper sheet and the lower sheet, the lower sheet configured to receive a second printing of second indicia for the one or more cards,
• wherein the upper sheet, the polymer core, and the lower sheet are configured to be cut into one or more cards,
• wherein one or more of the upper sheet, the polymer core, or the lower sheet includes inorganic particles dispersed in a polymer binder, wherein one or more of (a) a first density of the inorganic particles is less than four times a second density of the polymer binder or (b) a mass-median-diameter (D50) of the inorganic particles is larger than ten microns in size.

A sheet assembly configured to be cut into one or more cards, the sheet assembly comprising:

• an upper sheet configured to receive a first printing of first indicia for the one or more cards;
• a polymer core coupled with the upper sheet;
• and
• a lower sheet configured to receive a second printing of second indicia for the one or more cards, the lower sheet coupled with the polymer core with the polymer core disposed between the upper sheet and the lower sheet,
• wherein one or more of the upper sheet, the polymer core, or the lower sheet is formed from a polymer binder with inorganic particles dispersed in the polymer binder with a first density of the inorganic particles being at least 5.5 grams per cubic centimeter but less than four times a second density of the polymer binder that is at least 1.4 grams per cubic centimeter.