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This is a record of a document published elsewhere, first published by the United States Patent and Trademark Office, as US-2026104688-A1, on 16 April 2026. OpenTechnical did not first disclose it. The identifier, hashes and timestamps below record what this library served and when, not when the material became public. View the original.

OT-2026-000000487

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

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Classification
Sensors, Controls & Machine Vision › Industrial Control
Original source
US-2026104688-A1, the United States Patent and Trademark Office, 16 April 2026
Document SHA-256
08208a8da98fbb0bdcb45c0e83413dc2a076e14424cf70de02ab99b4abef0920

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.

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Citation

OpenTechnical Publication OT-2026-000000487, “Pre-singulated metal card template for accelerated singulation and waste reduction,” published September 15, 2026 at 19:02:57 UTC, https://opentechnical.org/p/OT-2026-000000487.

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