Standard EPC Gen2 RFID tags are made up of an integrated circuit (IC or chip) and a passive tag antenna (together called an inlay). Most often these are integrated into a label material. The key differentiating features of these tags are antenna design and storage capacity; the same label “packaging” can be used on any standard inlay. Often referred to as "Smart Labels", these are the tags most associated with supply chain applications such as those promoted by Wal-Mart and the US Department of Defense.

For more demanding applications (e.g. on-metal, high durability, etc.) the tag development is more complex and requires a different design and manufacturing approach. To understand these complexities consider the following:

Tag Antennas – Standard RFID inlays are two dimensional and are integrated into labels using high-speed converting equipment. However, standard RFID labels are not durable and will not work when placed directly on metal. Hard tags are three dimensional and can not be manufactured using high speed equipment.

Some organizations offer tags that use a standard RFID inlay with a plastic or foam “stand off” material that separates the inlay from the metal. These tags tend to perform poorly as the inlay was not designed for these applications. High performance hard tags incorporate more sophisticated antenna designs that allow them to perform significantly better in these demanding environments.
Packaging – As application requirements become more demanding the materials and processes used to manufacture the tags become more complex. High temperature tags require more exotic encapsulation materials and adhesives. Tags that are required to have a small footprint without compromising performance require even more exotic materials. The more exotic the material, the more expensive the tag.

Performance – Longer read distances require larger tag antennas (large antenna = large tag). Large tags require more materials and cost more to produce.

IC or Chip – Durable and On-Metal EPC Gen2 tags (aka “Hard” tags) use the same IC’s used on standard inlays. However, where automated equipment can be used to attach chips to standard inlays, the chip attachment process for durable tags is generally less automated. This also adds to the cost of the tags and can impact delivery times for larger orders.

The items listed above are by no means all inclusive – several other factors can impact the cost and availability of durable EPC Gen2 tags for the more demanding applications. The best advice we can offer is as follows:

• Make sure you have clearly defined your requirements. Important considerations include the materials being tagged (e.g. plastic, metal, etc.), environmental durability (e.g. temperature, chemical resistance, etc.), and performance requirements.
• Tag attachment preferences (e.g. adhesive, rivets, lanyards). The tag most appropriate for your application may not support your preferred attachment method off the shelf.
• Test the tags in your application environment. There are several organizations that sell product performance reports for a tidy fee. Unless your application will be deployed in a lab environment these reports are of little value. Identify tags that match your requirements and test them in your environment.

It is always best if an off the shelf tag is available to support your needs. In cases where an off the shelf solution is not available we can work with your team to review your options. You can be assured that we will do whatever it takes to help assure your project is a success.

Contact us any time we can be of assistance.