Teslin® vs PVC: Choosing the Right Material for Custom Cards

Teslin® was developed for durable, long-life card applications, including national identification and credential programs. SSI Cards laminates Teslin® with polyester to produce flexible, long-lasting cards with high-quality variable printing.

It is especially well suited for loyalty cards, membership cards, key tags, gift cards, direct-mail postcards, promotional cards, and detachable break-off offers. PVC is generally used only when a legacy card standard explicitly requires it, such as certain payment, financial, or access-control applications. For many other card uses, laminated Teslin® offers greater durability and flexibility, while PVC’s primary advantage can be lower material cost.

Need help choosing the right card material? Request free print samples to compare options, or get a custom quote for your project.

Teslin® vs PVC Cards: Key Differences

Myths About PVC Myths About Teslin® Facts
Meets all ISO, ANSI, Credit Card, and ABA standards for transaction cards. Does not meet ISO, ANSI, Credit Card, and ABA standards for transaction cards. The truth is that Teslin meets all standards that do not specifically require PVC.
Has clean, precision, optically die cut edges and round (corners?) Has rough, burred, steel rule die cut edges and corners. Teslin and PVC may be die cut with either steel rule or male/female die cutters. Unusual shapes require steel die rules.
Has superior, 4 color print detail, with brighter, more vibrant reproduction. Has duller, 4 color flow print with grainy reproduction. Teslin is printed by off-set with superior color consistency.
Will pop back into shape if accidentally bent or folded. Will permanently crease if accidentally bent or folded. PVC breaks when bent. Teslin is far more forgiving, due to elasticity of polyester lamination.
The PVC card is shipped ready to use. It is environmentally friendly, with no wasteful by-product. The Teslin card must be taken apart from its die-cut shell at time of issuance, leaving a wasteful, environmentally unfriendly by-product.PVC testing by several governments has also shown that children can ingest hazardous chemicals from PVC toys during use. Governments and industry are taking action to eliminate PVC. Danish and Swedish governments are restricting PVC use, hundreds of communities worldwide are eliminating PVC in buildings and many companies such as Nike, IKEA and The Body Shop have committed to eliminating PVC from their products.Green peace is campaigning to phase out PVC in favor of more environmentally friendly alternatives. Both PVC and Teslin® gift card products require a “hangar.”PVC is an environmental health disaster, posing major health hazards in its manufacturing releasing DIOXIN the most environmentally damaging plastic toxin known to man. Less than 1% is recycled, SEE GREENPEACE WEB SITE. Teslin® is a synthetic paper product and Polyester laminate a by-product of petroleum. Polyester and Teslin® have a reputation of being environmentally friendly.
PVC cards are laminated using a high-temperature, heat-lamination process. Vinyl over laminate film is scuff and scratch resistant. Teslin® cards are laminated using the soft adhesive lamination process. TESLIN® CARDS ARE GUARANTEED FOR 10 YEARS against breakage because of the superiority of lamination. PVC cards do not offer any guarantee.
Magnetic stripes are embedded in the film laminate, minimizing wear to reader heads. Magnetic stripes are applied to the card surface, leading to faster wear of the reader heads. Magnetic material is identical for Teslin® and PVC. Both are applied using heavy tonnage and there has never been a complaint recorded of “faster wear of reader heads” on Teslin® cards. Over 500 million Teslin® magnetic stripe cards have been produced.
PVC is the only substrate used for secure card applications i.e. Visa, Amex, ATM cards, and hotel door keys. Teslin® does not meet those standards. True. VISA, Amex, and ATM all have standards that specifically require PVC. It is doubtful if any Teslin® manufacturer has an interest in the alteration of that standard that dates back to the 1960’s.

Carwash gift card and loyalty card.

Best Uses for Teslin® Cards

Teslin® cards are well suited for applications that need durability, high-quality print reproduction, customization, and a more substantial feel than an ordinary paper card. SSI Cards produces Teslin®-based cards for a wide range of business and direct-mail uses.

  • Custom gift cards for retail, restaurants, hospitality, and customer rewards. 
  • Loyalty cards and key tags that customers can carry and use repeatedly. 
  • Membership cards, referral cards, appointment cards, and promotional cards. 
  • AcclaimMailer™ laminated plastic postcards with detachable wallet-size coupons, cards, offers, and key tags. 
  • Custom die-cut cards and break-off components for offers shaped around a product, promotion, or brand. 
  • Magnetic-stripe card applications where PVC is not explicitly required. 

BBQ Restaurant NVIO™ biodegradable eco-friendly CR80 gift card

A PVC-Free Card Option

SSI Cards’ Teslin® cards are made from synthetic paper with polyester lamination, not PVC. That construction supports durable card products while avoiding PVC in many direct-mail, gift-card, loyalty-card, and promotional-card applications.

For projects that specifically require a biodegradable material option, NVIO™ biodegradable cards provide an additional PVC-free alternative. NVIO™ can be used for durable card applications and premium direct-mail formats where sustainability is a primary project consideration.

Loyalty cards for dog grooming and automotive servicing, featuring two detachable key tags on the dog grooming card and one detachable key tag on the automotive servicing card.

When to Choose Teslin® vs PVC Cards 

The correct material depends on what the card must do.

Choose Teslin® when you need a durable, premium card for marketing, loyalty, gift-card, membership, direct-mail, or promotional applications and no governing specification requires PVC.

Choose PVC when a required card standard explicitly calls for it, such as certain payment-card, financial-card, or access-control applications.

If you are unsure which material fits your project, SSI Cards can help evaluate the intended use, customization requirements, card thickness, magnetic-stripe needs, die-cut options, and mailing or fulfillment requirements.

Assorted Teslin® loyalty cards and key tags.

Request Samples or Pricing

Compare the look, feel, and durability of SSI Cards’ card materials before you commit to production. Request free print samples or get a custom quote for Teslin®, NVIO™, gift cards, loyalty cards, key tags, or a custom direct-mail project.

Choosing the Right Material for Custom Cards FAQs

Are Teslin® Cards More Durable Than PVC Cards?

Explain that durability depends on construction and use, but laminated Teslin offers strong flexibility, print protection, and resistance to cracking and delamination.

Can Teslin® Cards Have Magnetic Stripes?

Answer yes, when the card design and intended system support the appropriate magnetic-stripe specification.

Are Teslin® Cards Waterproof?

Avoid an unqualified “yes.” Explain that properly laminated Teslin cards provide strong moisture resistance, but performance depends on construction, edges, lamination, and exposure.

Are Teslin® Cards Made of Plastic?

Explain that Teslin is a microporous synthetic paper made from a polyolefin-silica matrix and that SSI Cards laminates it with polyester for finished card products.

Which Is Less Expensive, Teslin® or PVC?

Explain that PVC may have a lower material cost, but total project cost depends on printing, lamination, customization, quantity, lifespan, mailing, and fulfillment.

Get started with a free quote

Call today to discuss your goals and create a custom program to drive new sales.

1.800.800.7741

REQUEST FREE QUOTE