High-Security Polycarbonate ID Card – Layered Production Files (Laser + Hologram)

I’m producing a corporate ID badge that sits on a 5-layer polycarbonate card and must pass directly into a Matica LCP-M600L printer running through CardExchange Producer. I already have the visual concept; what I need from you is a production-ready Adobe Illustrator document whose layers and registrations are flawless so the manufacturing line can run without tweaks.

The card includes retransfer CMYK, UV ink, tactile laser engraving, an over-laminated hologram, OVI / colour-shift graphics, CLI/MLI windows and microtext. High-security elements are the priority, so every security feature needs its own correctly named layer, aligned to the card’s reference grid and embedded with the proper spot colours or stroke settings that the machine expects.

Deliverables
• One .ai file organised by print stage (CMYK print, UV fluorescent, laser-engrave, hologram mask, OVI spot, CLI/MLI mask, microtext)
• Registration and crop marks positioned for the Matica 86 × 54 mm card profile
• A brief layer legend explaining colour swatches, blend modes and any overprint settings

When you respond, please confirm whether you have already built laser-engraved polycarbonate files and outline, in a sentence or two, how you normally structure layers for print, UV, laser and hologram work. Only designers with proven secure-card production experience should apply.