Multi-layer metal hybrid transaction card and process for manufacture

A smart card, blank smart card, or smart card intermediate comprising:

• a substrate layer having opposite surfaces, a periphery;
• at least one graphics layer having an outer-facing surface and an inner-facing surface;
• and
• a molded plastic material bonded to the at least one graphics layer and having a first portion extending over the outer-facing surface of the at least one graphics layer, a second portion extending between the inner-facing surface at least one graphics layer and one of the opposite surfaces of the substrate layer, and one or more interconnecting portions extending into the substrate layer.

A smart card, blank smart card, or smart card intermediate comprising:

• a metal substrate layer having a top surface, a bottom surface, a periphery, at least one hole, and a discontinuity extending from the top surface to the bottom surface and from the at least one hole to the periphery;
• a top graphics layer having an outer-facing surface and an inner-facing surface;
• a bottom graphics layer having an outer-facing surface and an inner-facing surface;
• and
• a molded plastic material bonded to the top graphics layer, the bottom graphics layer, and the metal substrate layer, the molded plastic material defining a first portion extending over the outer-facing surface of the top graphics layer, a second portion extending between the inner-facing surface of the top graphics layer the top surface of the metal layer, a third portion extending between the inner-facing surface of the bottom graphics layer and the bottom surface of the metal layer, a fourth portion extending over the outer-facing surface of the bottom graphics layer, and one or more interconnecting portions connecting the second portion to the third portion extending at least through the at least one hole and the discontinuity.