Contact smart cards having a document core, contactless smart cards including multi-layered structure, pet-based identification document, and methods of making same

A method of milling a cavity in an identification document to receive a smart card module, the identification document comprising at least a laminate layer-document core sandwich structure, wherein the laminate layer comprises a substantially different material than does the document core, said method comprising:

• providing a first cut in the laminate layer to create a rough upper cavity, the rough upper cavity including a first aperture;
• providing second cut to create a lower cavity, the lower cavity extending through the laminate layer into the document core, the lower cavity and the rough upper cavity being approximately centered on a common axis, wherein the aperture of the lower cavity is relatively smaller than the aperture of the rough upper cavity resulting in a shelf in the laminate layer;
• and
• providing a third cut around the rough upper cavity to create a finished upper cavity, the finished upper cavity having an aperture, which is larger than the aperture of the rough upper cavity, the finished upper cavity being approximately centered on the common axis.

A method of making a contactless smart identification document comprising:

• providing a carrier layer including at least a transceiver and electronic circuitry, wherein the carrier comprises at least one permeable area;
• arranging the carrier layer between a first contact layer and a second contact layer, and then securing the first contact layer and second contact layer to the carrier layer through at least one of heat and pressure so that at least a portion of one of the first contact layer and the second contact layer migrates into the carrier layer at the one permeable area;
• and
• providing a laminate layer over at least the first and second contact layers.

An identification document comprising:

• a first PET (polyethylene terephthalate) film including a top surface and a bottom surface;
• a second PET film including a top surface and a bottom surface;
• an image-receiving layer provided on the first PET film top surface;
• and an adhesive layer in contact with the first PET film bottom surface and the second PET film top surface, the adhesive serving to secure the first PET film to the second PET film.