Why Card Thickness Matters When Choosing a Printer
3rd Jun 2025
When it comes to ID card printing, it’s easy to focus on the big things—print quality, color, durability, and printer speed. But one factor that’s just as important (and often overlooked) is card thickness. Whether you’re printing employee badges, access cards, or membership IDs, the thickness of your cards can affect compatibility, performance, and long-term reliability.
In this blog, we’ll explore why card thickness matters, how it affects your printer choice, and what to consider when selecting cards and printers that work together seamlessly.
What Is Card Thickness?
Card thickness is typically measured in mils—1 mil equals 0.001 inch. The most common thickness for ID cards is 30 mil (0.030 inches), which is about the same as a standard credit card.
Here’s a breakdown of standard thicknesses:
| Card Thickness | Common Use |
|---|---|
| 10–15 mil | Temporary badges, business cards, key tags |
| 20 mil | Light-use ID cards, library cards |
| 30 mil | Standard employee/student IDs, access cards, driver’s licenses |
| 40–60 mil | High-durability applications, government IDs, dual cards (e.g., with embedded tech or layers) |
Why Card Thickness Affects Printer Choice
Not all ID card printers are built to handle every card thickness. Some are designed for standard 30-mil cards only, while others offer adjustable settings to accommodate thinner or thicker cards.
1. Card Feed and Roller Mechanisms
Printers use rollers to pull cards through the printing path. If the card is too thick (or too thin) for the rollers, it may jam, misfeed, or print incorrectly.
2. Ribbon-to-Card Contact
For high-quality printing, the ribbon must make firm contact with the card. A mismatch in card thickness can result in blurry prints, poor color transfer, or incomplete images.
3. Lamination & Overlays
Thicker cards may require different lamination settings or modules, especially if you’re using protective overlays or security laminates. Not all printers support lamination for non-standard thicknesses.
4. Encoding Capabilities
Some smart cards and proximity cards are slightly thicker due to embedded electronics. If your printer encodes cards (magnetic stripe, RFID, etc.), it must be compatible with both the card thickness and technology.
Things to Consider When Choosing a Printer Based on Card Thickness
What kind of cards will you be printing?
Are they access control cards, loyalty cards, or disposable visitor passes? This helps determine whether you need 10 mil, 30 mil, or something more specialized.
Will you need to print on multiple thicknesses?
If your program uses different cards for visitors, staff, and contractors, consider a printer that supports adjustable card thickness.
Are your cards pre-punched or embossed?
These features often add slight variation to card thickness—and may require a printer with specific feeding capabilities.
Are you using smart cards or proximity cards?
Check the printer’s specs to confirm compatibility with clamshell cards, composite cards, or any card with an embedded chip or antenna.
How to Find the Right Printer for Your Card Type
When shopping for an ID card printer, always review the supported card thickness range in the technical specifications. Most standard printers support 20–40 mil cards, but some high-end models offer wider ranges for specialty use.
You’ll also want to consider:
- Adjustable card thickness settings
- Manual or automatic card feeding
- Dual-side printing support for thicker cards
- Optional encoding or lamination modules
Need help matching your card stock with the right printer? That’s where we come in.
Final Thoughts
Card thickness might seem like a small detail, but it has a big impact on your printing process. Choosing a printer that supports the correct card thickness ensures smoother operation, better quality prints, and longer-lasting equipment.
Whether you’re printing standard 30-mil photo IDs or thick, encoded credentials, the right printer makes all the difference.
Not sure what printer fits your card stock? Contact us today and we’ll help you choose the right solution for your card program—whether you need help selecting a printer, ribbons, or supplies.