How Is US Currency Made: The Complete Production Process

The Bureau of Engraving and Printing (BEP) and the United States Mint are responsible for producing US currency. They use a combination of old and new technologies to create the paper and coins we use every day.

Security features are built into every note to prevent counterfeiting. These features include watermarks, color-shifting ink, and microprinting.

At the BEP, large rolls of paper are cut into individual sheets, which are then printed with the design and security features. Each sheet is carefully inspected to ensure it meets the high standards of the US government.

The paper used for US currency is made from 75% cotton and 25% linen, giving it a unique texture and durability. This special paper is designed to withstand the wear and tear of being handled and used frequently.

The Bureau of Engraving and Printing (BEP) in Washington D.C. produces $1, $2, $5, $10, $20, $50, and $100 bills, while the Federal Reserve Bank in Fort Worth, Texas, produces $1, $2, $5, $10, $20, $50, and $100 bills.

The process of making US currency starts with designing the new bills, which involves creating the color palette, security features, and other design elements.

The BEP uses a combination of paper and synthetic materials to create the paper for US currency, which is made to be durable and resistant to wear and tear.

The paper is then cut into individual sheets, which are then printed with the design elements using intaglio printing, a process that involves etching the design onto a metal plate.

The BEP produces over 38 million notes per day, with a total of 7.2 billion notes printed annually.

Security threads are woven into the paper to prevent counterfeiting, and the threads glow pink when held under UV light.

The BEP also adds watermarks to the paper, which can be seen when held up to light.

The serial numbers on US currency are assigned randomly to prevent tracking of large transactions.

The BEP uses a specialized ink that is resistant to fading and wear, ensuring that the design elements remain clear and visible over time.

The BEP also adds microprinting to the bills, which is extremely small text that can only be seen under magnification.

The Federal Reserve Bank in Fort Worth, Texas, is responsible for distributing the printed currency to banks and financial institutions across the country.

The design of US currency is a meticulous process that involves hand-tooling by engravers working from a drawing or photograph. Each engraver is responsible for a single portion of the design, such as the portrait or numerals.

The portrait on the face of each bill varies by denomination, with famous historical figures like George Washington, Abraham Lincoln, and Benjamin Franklin appearing on the $1, $5, and $100 bills, respectively. By law, no portrait of a living person may appear on paper money.

In 1955, Congress passed a law requiring that the words "In God We Trust" appear on all US currency and coins, which first appeared on bills in 1957. The inscription now appears on the back of all paper money.

The Bureau of Engraving and Printing, part of the Department of the Treasury, is responsible for engraving and printing all US currency. They produce approximately 38 million pieces of paper money every day, with 45% being $1 bills and 25% being $20 bills.

Each bill, regardless of its denomination, costs the government about 3.8 cents to produce. The production process involves 65 separate operations, with the highest level of protection given to the $100 bill due to its large denomination and frequent counterfeiting outside the US.

The paper blend used in US currency is a unique combination of cotton and linen, making up 75% and 25% of the blend, respectively. This special blend gives the currency a distinct feel and a high level of durability.

The paper is also embedded with various security features during its production, such as watermarks and security threads. These features are integral to the currency's design and security.

The paper blend has a special feel to it, which is noticeable when handling US currency. This is due to the unique combination of cotton and linen.

Starting in 1990, the paper for $10 bills and higher denominations was made of two plies with a polymer security thread laminated between them. The thread was added to $5 bills in 1993.

The paper blend is not only important for the feel and durability of the currency, but also for its security features.

The Bureau of Engraving and Printing in the United States is responsible for engraving and printing all paper money. This includes printing postage stamps, savings bonds, treasury notes, and other items.

The main production facility is located in Washington, D.C., and there is a smaller facility in Fort Worth, Texas. Every day, the Bureau prints approximately 38 million pieces of paper money.

About 45% of this production are $1 bills and 25% are $20 bills. The rest of the production is divided between $5, $10, $50, and $100 bills. Although the $2 bill is still in circulation, it is rarely used, and therefore is rarely printed.

Each bill, regardless of its denomination, costs the government about 3.8 cents to produce. There are 65 separate operations in the production of paper money.

Paper money has some amazing security features that make it difficult to counterfeit.

The special paper used in currency production has a unique feel to it, making it hard for counterfeiters to replicate.

Embedded security features in the paper add layers of complexity that safeguard against counterfeiting.

The distinctive properties of the ink used in currency production also play a significant role in the currency's security.

The combination of special paper and ink plays a significant role in the currency's security, making it difficult for counterfeiters to replicate. The unique feel of the paper, along with the distinctive properties of the ink, adds layers of complexity that safeguard against counterfeiting.

Specialized ink and embedded security features in the paper ensure the originality of banknotes. These features add complexity that makes it hard for counterfeiters to replicate the unique feel and ink properties.

Modern currency production employs sophisticated technologies for inspection, including high-speed cameras and sensors that scan each note for consistency in color, design, and alignment. These systems can detect even the most minute discrepancies that might be invisible to the naked eye.

The colored Treasury seal and serial numbers are an essential part of paper money. They're printed using a precise process that ensures they're perfectly aligned and clearly visible.

The Treasury seal is printed in color, and the serial numbers are printed simultaneously on the face of the bills. Sixteen serial numbers are printed at the same time, and the numbers on any sheet are separated by 20,000 between adjacent bills.

The printing process involves a letterpress that automatically advances the numbers before the next sheet of sixteen is printed. This ensures that the bills within each stack will have sequential serial numbers when the sheets are cut into separate stacks.

The finished sheets are inspected with machine sensors to detect any printing errors, folded paper, or foreign objects. Any defective bills are marked for later removal and replaced with star notes that have a different sequence and a star printed after the serial number.

Here's an example of how the serial numbers are printed:

This pattern continues, with each sheet having sequential serial numbers. The ink used for overprinting is specially formulated to be distinct and durable, ensuring that these critical elements remain legible throughout the life of the note.

The combination of special paper and ink plays a significant role in the currency's security, making it difficult for counterfeiters to replicate.

The unique feel of the paper, along with the distinctive properties of the ink, adds layers of complexity that safeguard against counterfeiting.

Embedded security features in the paper, combined with the specialized ink, make it challenging for counterfeiters to create convincing replicas.

High-speed cameras and sensors scan each note for consistency in color, design, and alignment, detecting even the most minute discrepancies that might be invisible to the naked eye.

The ink used in currency printing is specially formulated to be long-lasting and resistant to fading, ensuring that the printed features remain legible throughout the life of the note.

Specialized ink formulations vary for different elements of the currency's design, such as color-shifting ink, which changes color when viewed from different angles.

The application of ink must be precise to ensure that the right amount of ink transfers to the paper, maintaining the clarity and texture of the printed features.

Around half of the bill, if examined against the light, features a dark transverse band with the value, which can hardly be counterfeited.

The process of adding serial numbers and seals involves precise printing techniques to ensure perfect alignment and clear printing, using specially formulated ink that is distinct and durable.

Plate making is a crucial stage in currency production where master plates created during siderography are used to produce the actual printing plates.

These printing plates are the tools that will directly imprint the currency's design onto the paper. The master plates are a result of a precise process that requires great care and attention to detail.

The printing plates are used to add the defining features to the currency, ensuring that each note is not only a work of art but also a secure and functional piece of financial infrastructure.

The complexity and precision of the designs added at this stage are difficult for counterfeiters to replicate accurately. This is one of the key reasons why plate printing plays a significant role in the currency's security.

The printing process is a crucial step in creating US currency. It involves several stages, starting with the preparation of metal plates that are engraved with the currency design.

These plates are then used in the Intaglio Printing Process, where ink is applied and transferred under high pressure to the currency paper. This process creates a raised texture that can be felt by touch.

The raised texture is a key security feature, as it's difficult to replicate without the specialized equipment used in this process. This is why you might notice that some currency notes have a unique feel to them.

In the printing stages, offset printing lays down the foundational colors and patterns, while plate printing adds the intricate details and tactile features. This combination of printing techniques ensures that the currency design is both visually appealing and secure.

The inspection process is also an important part of the printing process, ensuring that each note meets stringent quality and security standards.

Quality control is a top priority in the production of US currency. The raw materials, such as ink and paper, are subject to strict inspections before they are used.

The inks are tested for color, viscosity, and other properties, ensuring they meet the exact standards required. The paper is produced by a single manufacturer in a secret, tightly controlled process, and is tested for chemical composition, thickness, and other properties.

It is estimated that a bill can be folded and crumpled up to 4,000 times before it has to be replaced, demonstrating the durability of the currency. The finished bills are also tested periodically for durability, with some bills being put through a washing machine to determine the colorfastness of the inks.

Consistency is key in currency production, and it's ensured through rigorous testing of the paper and ink used in U.S. currency.

The quality of the paper and ink is tested to ensure consistency across all currency notes, which is vital for maintaining public confidence in the currency.

Automated handling systems, such as ATMs and sorting machines, rely on this consistency to operate effectively.

The paper and ink used in U.S. currency contribute to the overall aesthetic, tactile feel, and security of the currency.

Throughout the offset printing process, printed sheets are continuously monitored for consistency in color, clarity, and alignment.

This level of scrutiny ensures that each batch of currency paper meets the exact standards required before moving on to the next phase of printing.

Offset printing plays a foundational role in currency production, setting the stage for the intricate and detailed work that follows.

The inspection process for currency is a rigorous one, involving a series of detailed checks to ensure each note meets the highest standards of quality.

Advanced machines and trained professionals work together to examine each note for imperfections, such as misprints, smudges, or misalignments that could have occurred during the printing stages. The precision required is incredibly high, as even the smallest flaw can render a note unfit for circulation.

The accuracy of the COPE stage is vital for the overall security of the currency, with equipment used to verify the accuracy of each overprint. Any notes that do not meet the stringent standards are automatically rejected and removed from the production line.

Quality control standards are strict, with inks tested for color, viscosity, and other properties, and paper produced by a single manufacturer in a secret, tightly controlled process. The paper is tested for chemical composition, thickness, and other properties.

The finished bills are also tested periodically for durability, with some bills put through a washing machine to determine the colorfastness of the inks, and others repeatedly rolled into a cylinder and crushed on end to determine their resistance to handling. It is estimated that a bill can be folded and crumpled up to 4,000 times before it has to be replaced.

The Large Examining Printing Equipment (LEPE) is a pivotal stage in modern currency production, representing a significant advancement in the efficiency and accuracy of printing and examining U.S. currency notes.

Throughout the offset printing process, stringent quality control measures are in place, with printed sheets continuously monitored for consistency in color, clarity, and alignment. This level of scrutiny ensures that each batch of currency paper meets the exact standards required before moving on to the next phase of printing.

The plates used in siderography must be precise in their replication of the design, with any deviation potentially compromising the effectiveness of the currency's security features. The plates are typically made from robust materials capable of maintaining their integrity over thousands of impressions without degrading the quality of the print.