Patent ID: 7288441

Claim:
A method for fabricating a card having a substrate having a circuit side and a back side, the substrate generally separated from a surrounding frame by a peripheral opening spanned by at least one connecting segment between the substrate and the frame, the substrate having at least one electrical circuit and at least one connector for communicating between the at least one electrical circuit and an external circuit, comprising: clamping the substrate and the frame between a first plate and a second plate of a first molding assembly forming a first mold cavity for injecting a first material into the first mold cavity for molding a first plastic casting onto the circuit side of the substrate and encapsulating the at least one electrical circuit while leaving a peripheral portion of the circuit side free of the first material, the first plastic casting having an exposed surface and clamping the frame, the substrate and the first plastic casting between a first plate and a second plate of a second molding assembly, at least a portion of the exposed surface of the first plastic casting compressed for sealingly engaging a portion of the back side of the substrate against the first plate of the second molding assembly, the first plate and the second plate of the second molding assembly forming a second mold cavity for injecting a second material into the second mold cavity for molding a second plastic casting surrounding the first plastic casting and enclosing the peripheral portion of the circuit side and an edge of the substrate, the second plastic casting having a peripheral outer edge; removing the card from the first mold cavity; and singulating the substrate from the frame.