Pre-singulated metal card template for accelerated singulation and waste reduction

Abstract

A method and system for the manufacturing of metal cards using a pre-singulated card-to-card tabbing structure that eliminates the need for a surrounding frame. The invention enables higher sheet utilization, reduced scrap material, and faster CNC milling by chemically or mechanically defining voids in a metal sheet that correspond to individual cards, each connected to adjacent cards via breakable struts or tabs. Additional features may include selective etching of cavities for magnetic stripes or EMV chips to allow flush mounting without post-assembly surface protrusions. The system supports a variety of card types, including financial, membership, access, and business cards, and accommodates multi-layer construction, resin infill, and lamination techniques. The invention also allows automated or manual insertion of components, enhanced bonding via etched sidewalls, and significant improvements in production efficiency, tool longevity, and final product durability.

Dependencies are inferred from the claim text.