Secure documents and methods of manufacturing the same

1. A method of manufacturing a secure document, comprising:

receiving a substrate in a roll format having a micro-replication lacquer applied to a first side of the substrate, the micro-replication lacquer comprising one or more features of a first thickness formed therein;

applying a substantially uniform thickness, less than the first thickness, of metal complex ink to the first side of the substrate thereby covering the micro-replication lacquer applied to the first side of the substrate; and

curing the metal complex ink within a predetermined amount of time of applying the metal complex ink to the first side of the substrate such that the applied metal complex ink substantially conforms to the micro-replication lacquer.

2. The method of claim 1 , further comprising:

applying a second layer to a second side of the substrate that opposes the first side of the substrate;

covering the metal complex ink with a third layer thereby sandwiching the substrate between the second layer and the third layer; and

laminating the substrate, second layer, and third layer.

3. The method of claim 2 , wherein the metal complex ink comprises a lower curing temperature than the substrate, the second layer, and the third layer.

4. The method of claim 1 , wherein the metal complex ink comprises particles having a diameter of no more than 10 nanometers.

5. The method of claim 4 , wherein the metal complex ink comprises a thickness of no more than 4 microns and wherein the metal complex ink is cured to create a mirror-like finish.

6. The method of claim 1 , wherein applying the metal complex ink to the first side of the substrate comprises printing the metal complex ink onto the first side of the substrate using one or more inkjet print heads.

7. The method of claim 1 , further comprising:

applying a second metal complex ink to the first side of the substrate, wherein the second metal complex ink is applied at substantially the same time as the metal complex ink.

8. The method of claim 7 , wherein the second metal complex ink comprises a different material than is provided in the metal complex ink.

9. The method of claim 7 , wherein the metal complex ink is applied with a first inkjet print head and the second metal complex ink is applied with a second inkjet print head.

10. The method of claim 1 , wherein the metal complex ink is cured by exposure to at least one of Ultraviolet (UV) light and Infrared (IR) light.

11. The method of claim 1 , further comprising:

providing at least one electronic component over the substrate;

covering the at least one electronic component with an additional layer of polycarbonate; and

laminating the additional layer of the polycarbonate to the substrate thereby fixing a position of the at least one electronic component between the substrate and the additional layer of polycarbonate.

12. A secure document, comprising:

a substrate having a micro-replication lacquer applied to a first side of the substrate, the micro-replication lacquer comprising one or more features of a first thickness formed therein; and

a substantially uniform thickness, less than the first thickness, of metal complex ink applied to the first side of the substrate thereby covering the micro-replication lacquer applied to the first side of the substrate;

wherein the metal complex ink is cured within a predetermined amount of time of application to the substrate such that the applied metal complex ink substantially conforms to the micro-replication lacquer; and

wherein the metal complex ink comprises a lower curing temperature than the substrate.

13. The secure document of claim 12 , wherein the metal complex ink is cured so as to exhibit a mirror-like finish.

14. The secure document of claim 12 , wherein the metal complex ink comprises a silver nanoparticle ink and wherein the substrate comprises at least one of polycarbonate, polycarbonate copolymer, and a blend of polycarbonate and polycarbonate copolymer.

15. The secure document of claim 12 , further comprising:

a second layer positioned adjacent to a second side of the substrate that opposes the first side of the substrate; and

a third layer positioned adjacent to the metal complex ink thereby sandwiching the substrate between the second layer and the third layer.

16. The secure document of claim 12 , further comprising:

a second metal complex ink applied adjacent to the metal complex ink.

17. A secure document, comprising:

a polycarbonate substrate;

an embossed lacquer provided on at least one surface of the polycarbonate substrate, the embossed lacquer comprising one or more features of a first thickness formed therein; and

a security feature provided on the polycarbonate substrate, wherein the security feature at least partially conforms to the embossed lacquer and comprises a first metal complex ink as well as a second metal complex ink printed on the polycarbonate substrate in a layer having a substantially uniform thickness, less than the first thickness, and cured within a predetermined amount of time of printing on the substrate, wherein the first metal complex ink and the second metal complex ink are positioned adjacent to one another thereby creating different visual effects for the security feature.

18. The secure document of claim 12 , wherein the applied metal complex ink substantially conforms to the micro-replication lacquer such that contours of an upper surface of the micro-replication lacquer created by the one or more features formed in the micro-replication lacquer create corresponding contours in an upper surface of the applied metal complex ink.

19. The secure document of claim 12 , wherein the applied metal complex ink substantially conforms to the micro-replication lacquer such that peaks and valleys of an upper surface of the micro-replication lacquer substantially translate to an upper surface of the applied metal complex ink.

20. The secure document of claim 12 , wherein curing the metal complex ink within a predetermined amount of time of application to the substrate such that the applied metal complex ink substantially conforms to the micro-replication lacquer creates a mirror-like finish on the applied metal complex ink interrupted by the one or more features of the micro-replication lacquer.