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Security thread

A security thread is a thin, polymer-based strip embedded into the paper substrate of banknotes during the manufacturing process to deter counterfeiting by providing a verifiable authentication feature visible under transmitted light.^[1] These threads typically incorporate advanced elements such as microtext, metallic coatings, holograms, color-shifting inks, or UV-fluorescent properties, making replication difficult without specialized equipment.^[2]^[1] Originating in the mid-1800s with simple silk threads introduced by Crane and Co. for early U.S. currency, security threads evolved significantly; by the 1940s, the Bank of England pioneered metallic versions for shilling notes, marking a shift toward more robust anti-forgery measures.^[1] In the United States, the Bureau of Engraving and Printing first incorporated security threads into Series 1990 $100 notes, embedding a clear plastic strip inscribed with "USA 100" to combat high-quality color photocopiers, with the feature later expanding to higher denominations by 1993.^[3] Today, security threads are a standard in over 90% of global banknotes, available in various configurations including fully embedded (latent) threads covered entirely by paper, diving threads that weave in and out of the surface, and windowed (figured) threads with periodic exposed sections for enhanced visibility.^[1]^[2] Notable examples include the Eurozone's 2017 series with magnetic security threads for machine readability, the Brazilian Real's 2020 metallized threads without text for subtle integration, and the U.S. Dollar's Series 2013 $100 note featuring a 3D security ribbon that creates the illusion of bells moving and a color-shifting bell in the inkwell when tilted.^[1]^[4] Beyond banknotes, similar threads are adapted for passports, IDs, and other high-security documents, combining public verification methods—like color shifts or 3D effects—with machine-detectable traits such as fluorescence or magnetism to elevate overall document integrity.^[2]

History

Invention and Early Development

Early security features in banknotes included embedded fibers, such as silk threads introduced by Crane and Co. in the mid-1800s for U.S. currency and jute or worsted fibers used in various notes from the 1860s to 1890s.^[5] The modern security thread, a metallic strip embedded within banknote paper, originated in the 1930s through a collaborative effort between Stanley Chamberlain, an engineer at the Bank of England Printing Works, and Portals Ltd., a prominent British paper manufacturer specializing in currency paper.^[5] This partnership aimed to innovate anti-counterfeiting measures amid growing threats from advanced reproduction technologies, particularly during the interwar period when forgery techniques were evolving rapidly.^[6] The primary purpose of the security thread was to integrate a detectable element into the paper substrate that would resist replication by lithographic presses and other advanced printing methods, thereby deterring counterfeiters who could otherwise mimic surface printing with relative ease, addressing vulnerabilities exposed by rising sophisticated printing capabilities in Europe.^[5] Chamberlain's design focused on embedding thin metallic strips during the papermaking process, creating a feature that was inconspicuous in normal handling but verifiable through simple inspection methods.^[6] Early prototypes, known as the "Chamberlain thread," consisted of basic metallic filaments incorporated into the paper pulp, lacking the optical or holographic enhancements of later iterations.^[5] These initial versions were engineered for visibility when the note was held to transmitted light, revealing a continuous or dashed line that confirmed authenticity without requiring specialized equipment.^[5] The first limited implementations occurred in the late 1930s and 1940s, primarily in British territories to combat wartime forgeries, such as the 1938 trial in South African £1 notes and the 1940 introduction in Bank of England £1 and 10-shilling notes.^[5] By 1944, the feature extended to British colonial currencies, marking its debut in Indian rupee notes as a novel security element amid World War II disruptions.^[7]

Widespread Adoption

The introduction of security threads into U.S. banknotes marked a pivotal moment in their widespread adoption, beginning with the Series 1990 $100 bill produced by the Bureau of Engraving and Printing, which represented the first federal implementation of this anti-counterfeiting feature.^[8] This addition was part of broader efforts to enhance currency security amid evolving technological threats.^[9] The 1990s saw rapid global uptake of security threads, driven by the surge in counterfeiting enabled by color photocopiers and digital printing presses, which made high-quality reproductions more accessible to illicit actors.^[10] Counterfeit incidents escalated, prompting central banks worldwide to integrate threads into new note series as a reliable, verifiable deterrent. By the mid-1990s, this response had accelerated adoption across multiple nations, establishing security threads as a standard feature in high-denomination bills. In Europe, the European Central Bank advanced this trend by incorporating security threads into the euro banknotes' initial designs launched in 1996, with the feature embedded in all seven denominations of the first series issued in 2002.^[11] The threads, visible as a dark line under transmitted light and bearing the euro symbol and value, were selected for their ease of public verification and resistance to replication.^[12] Security threads had spread widely by 2000. These efforts ensured that threads became a cornerstone of modern banknote design, appearing in approximately 95% of circulating currencies as of 2020.^[6]

Design and Features

Basic Components and Materials

A security thread consists of a thin strip, typically 1 to 3 mm wide, embedded lengthwise within the paper substrate of a banknote to provide an integrated security feature. This core structure ensures the thread is concealed under reflected light but becomes visible as a continuous line when the note is held up to transmitted light, enhancing its role in authentication. The embedding process integrates the thread seamlessly with the surrounding fibers during papermaking, maintaining the note's uniform thickness and tactile feel.^[13]^[14] The primary materials used in security threads are polyester films, such as polyethylene terephthalate, which serve as a durable, flexible base substrate. These films are commonly coated with a thin layer of aluminum, applied via vacuum deposition to a thickness of approximately 300-400 angstroms, imparting reflectivity and metallic sheen for visual verification. In some designs, additional pigmented resins insoluble in common solvents like ethyl alcohol or water are applied over the metallized surface to protect against tampering attempts and ensure color matching with the banknote paper. Metallic alloys may also be incorporated for enhanced tamper resistance, though polyester-aluminum combinations predominate due to their balance of flexibility and security.^[15]^[13]^[16] Key functional elements of security threads include microprinting etched along the strip's length, which requires magnification for verification and resists reproduction by standard printing methods. Demetallized sections, created by selectively removing portions of the aluminum coating through chemical etching (e.g., using sodium hydroxide solutions), reveal fine text, patterns, or denominational indicators that are legible only under transmitted light. These elements leverage the thread's metallized properties to create high-contrast visuals, making forgery challenging without specialized equipment.^[15]^[13]^[16] Engineering considerations for security threads emphasize durability to endure repeated handling, folding, and environmental exposure. The polyester base provides high tensile strength, often exceeding that of the surrounding paper to prevent tearing along the thread line during use. Materials are selected for resistance to chemical attacks, such as bleaching agents, with protective coatings ensuring the thread remains intact and functional even under attempted alterations. These properties collectively contribute to the thread's longevity, typically matching or surpassing the banknote's overall lifespan of several years in circulation.^[17]^[15]^[16]

Types and Variations

Security threads in banknotes are categorized primarily by their embedding patterns and visibility, which determine their authentication methods and resistance to counterfeiting. The main types include latent, windowed, and diving (also known as fluttering) threads, each offering distinct optical properties for public and machine verification. Advanced variations incorporate additional effects like holography, iridescence, and fluorescence to enhance security levels. Latent threads consist of fully embedded solid strips integrated completely within the paper substrate during manufacturing, rendering them invisible in reflected light but detectable as a continuous line when the banknote is held up to transmitted light. This design provides basic authentication by requiring backlighting for visibility, making replication challenging without specialized equipment. They were first introduced in early United States banknotes, such as the Series 1990 $100 notes, where the thread appears as a dark stripe under light and includes microprinted denomination indicators. Windowed threads feature partial exposure at regular intervals along the banknote's surface, creating visible segments that alternate with embedded sections, allowing for direct visual and tactile inspection without additional tools. These exposed "windows" often contain metallic or printed elements that shimmer or display text, facilitating quick public checks while the embedded portions add covert security. This configuration has been employed in Australian dollar notes since 1988, particularly in polymer substrates where the thread integrates with clear windows for enhanced overt features.^[18] Diving, or fluttering, threads alternate irregularly between fully embedded and surface-exposed sections, producing a wavy or dotted appearance on the note that complicates precise duplication by counterfeiters due to the non-uniform pattern. When viewed in transmitted light, the entire thread becomes a solid line, but the irregular surfacing creates dynamic visual effects under normal lighting. This type is featured in banknotes such as the Tajikistani somoni, where the thread embeds with intermittent exposures.^[19] Advanced variations build on these base types by incorporating optical effects for higher security. Holographic threads embed diffractive optically variable devices (OVDs) that project three-dimensional images or motion effects when tilted, with the first holographic thread appearing on a banknote in 1992 and now common in thread formats for their machine-readable and visually striking authentication.^[20] Iridescent threads utilize color-shifting materials, such as thin-film interference coatings, that change hues under varying angles of light, providing an additional layer of overt verification resistant to scanning or photocopying. UV-fluorescent threads, meanwhile, remain covert under normal conditions but emit specific glows when exposed to ultraviolet light; for instance, the security thread in the United States $10 note fluoresces orange, aiding forensic detection while maintaining subtlety in everyday use. These enhancements, often combined with base embedding styles, elevate the thread's role in multi-level security systems. As of 2025, recent innovations include multi-colored diffractive threads with dynamic effects for improved verification, as in Kazakhstan's tenge series.^[21]

Manufacturing and Integration

Production Techniques

Security threads are primarily fabricated through vacuum metallization, a process in which a thin layer of aluminum, typically 20-50 nm thick, is deposited onto a plastic film substrate, such as polyester, within a controlled vacuum chamber to ensure high reflectivity and uniformity.^[15]^[22] This evaporation technique, often using thermal or electron-beam sources, allows the metal to condense evenly on the film's surface, creating a metallic appearance essential for overt security features. Following metallization, printing and patterning techniques are applied to embed security elements like microtext or holograms directly onto the thread. Demetallization, a selective removal process, is commonly used to create transparent patterns or microtext by applying a resist layer and etching away metal in precise areas, achieving resolutions as fine as 100 microns for machine-readable indicia.^[1] For holographic effects, laser etching or embossing followed by partial metallization patterns diffractive structures, enhancing visual complexity without compromising the thread's flexibility.^[23] These methods, including photolithographic resists for high-precision patterning, ensure features are difficult to replicate using standard printing equipment.^[24] Quality control during production is critical to maintain thread integrity and performance. Adhesion strength testing, such as tensile or shear tests, verifies the bond between the metal layer and substrate, ensuring no delamination occurs under mechanical stress, with failure thresholds set to prevent thread breakage during handling.^[25] Since 2000, innovations have focused on advanced materials to enhance security and sustainability. Nano-inks incorporating nanostructures enable color-shifting effects through interference patterns, producing dynamic visual changes under different angles or lighting, as seen in threads like RollingStar Venus.^[26] As of 2025, security threads incorporating recycled PET and aluminum, such as the Optomove® micro-optics thread, further advance sustainability efforts.^[27]

Incorporation into Banknotes

Security threads are integrated into banknote paper primarily during the Fourdrinier papermaking process, where the threads are fed continuously from bobbins into the wet pulp slurry on the forming wire at precise intervals using automated guides and insertion tubes.^[28] This embedding occurs in the initial wet stage of production, allowing the pulp fibers to envelop the thread as the sheet forms and dewaters, ensuring secure integration without disrupting the continuous web formation.^[29] Positioning of the security thread requires high accuracy, with alignment parallel to the note's edges maintained within tolerances of ±0.3 mm to prevent misalignment during subsequent printing operations.^[30] Automated tension control mechanisms, including brakes and sensors, stabilize the thread feed to counteract the machine's oscillatory shaking, which could otherwise cause meandering or displacement.^[28] Following embedding, the paper undergoes post-processing treatments to enhance durability and security. Calendering, where the dry sheet passes through polished metal rolls under pressure, smooths the surface, compacts the fibers, and strengthens the bond between the thread and surrounding pulp, imparting a uniform polish essential for high-quality banknotes.^[31] For windowed threads with exposed sections, additional protection is provided by applying specialized security inks over these areas during or after initial drying, which can include optically variable or fluorescent properties to augment authentication without compromising the thread's visibility.^[2] Key challenges in this incorporation process include preventing thread breakage during high-speed production, where machines operate at 50-90 m/min, necessitating precise tension adjustments (typically 0.12-1.58 g/mm²) to handle the dynamic forces on the delicate polymer or metallized strips.^[28]^[32] Furthermore, ensuring compatibility with downstream intaglio printing presses demands exact thread placement to avoid interference with raised ink impressions or registration errors, as even minor deviations could render the note unusable or easier to counterfeit.^[33]

Applications and Examples

Use in Major Currencies

The security thread in United States dollar banknotes was first introduced in the $100 denomination in 1990 as a plastic strip embedded in the paper, featuring microprinted "USA 100" repeating alternately and visible from both sides when held to light; under ultraviolet light, it glows pink to aid verification. This feature enhanced the note's resistance to counterfeiting by providing a machine-readable and visually distinct element. In the 2013 series redesign, the thread evolved into a 3D security ribbon woven into the paper, displaying bells and "100s" in copper-colored ink that shift and move when tilted, combining diffractive optics for added complexity.^[34] Eurozone banknotes incorporate windowed security threads across denominations from €5 to €500, introduced with the first series in 2002 as an embedded metallic strip visible as a dark line when held to light, bearing the word "EURO" and the denomination value repeated. The Europa series, launched progressively from 2013, upgraded these to holographic windowed threads at the top of the note, featuring a portrait of Europa from Greek mythology alongside the denomination, which reveals shifting colors and images under tilt for enhanced authentication. These elements are partially exposed in a clear window, allowing public inspection without special tools. The British pound sterling's polymer banknotes, introduced starting with the £5 in 2016, utilize metallized security strips integrated into the transparent windows, displaying metallic portraits of Queen Elizabeth II (or King Charles III in newer issues) surrounded by the denomination and "Bank of England" text in gold, silver, or colored foils that shimmer when tilted.^[35] For the £10, £20, and £50 notes, additional holographic patches below the main window switch between the value and "£" symbol, with the strip's diffractive properties ensuring visibility from both sides.^[35] This design marks a shift from paper notes, leveraging the polymer substrate for durable, window-exposed threads that resist wear while maintaining overt security cues. Other major currencies employ similar innovations; for instance, the Canadian dollar's polymer series, launched in 2011, features a large transparent maple leaf window with integrated holographic elements displaying shifting numbers and maple leaves, as well as microprinted text that fluoresces under UV light, for denomination-specific verification across $5 to $100 notes. In India, the Mahatma Gandhi (New) series post-2016 includes fluorescent security threads in denominations like ₹500 and ₹2000, which glow yellow-green under UV and bear alternating "Bharat" and "RBI" inscriptions, positioned to the left of the portrait for easy alignment checks.^[36]

Evolution in Specific Denominations

The United States $100 Federal Reserve Note marked a significant advancement in security thread technology with its 1990 series introduction of a basic embedded plastic strip running vertically through the bill, visible under transmitted light and bearing microprinted "USA 100" text to deter counterfeiting.^[4] This feature was retained and refined in the 1996 redesign, where the thread remained a core element alongside color-shifting ink, but it evolved dramatically in the 2013 redesign to a blue 3D security ribbon woven into the paper. The ribbon incorporates motion effects, displaying shifting bells and "100" numerals that appear to move when tilted, enhancing visual verification and contributing to an over 85% decline in $100 counterfeits since the 1990s.^[37]^[38] In the eurozone, the €20 banknote's first series, issued in 2002, featured a simple embedded security thread appearing as a dark stripe under light, with microtext of the denomination and € symbol for basic authentication.^[39] The 2019 Europa series upgrade transformed this into a holographic strip—a wider, continuous metallic band with perforations forming the € symbol and shifting colors from green to blue upon tilting, integrated with a portrait hologram of Europa for multilayered optical security.^[40] Australia's $50 note transitioned from paper substrates pre-1995, which incorporated metallic security threads embedded for opacity and tactile detection, to polymer construction in 1995, featuring fully windowed threads visible through transparent sections of the plastic base.^[41] This shift enabled more intricate designs, such as diffractive optically variable devices within the window that display color-shifting images, further advanced in the 2018 redesign with iridescent patches and microprinted elements along the thread for superior counterfeit resistance.^[42] The Japanese 10,000 yen note's 2004 series D redesign introduced latent threads with embedded latent images, where tilting reveals hidden "10000" numerals and "NIPPON" text in a vertical band, combining intaglio printing for depth and fluorescence under UV light.^[43] By the 2024 new series issuance, these evolved to include iridescent pearl ink patterns that shimmer pink in blank areas and advanced 3D holograms with dynamic color shifts, bolstering anti-counterfeiting through enhanced optical variability.^[44]

Detection and Security Role

Verification Methods

Verification of security threads in banknotes primarily relies on simple, accessible techniques that reveal their embedded nature, optical properties, and fine details, distinguishing genuine notes from counterfeits.^[45]^[12] Visual inspection begins by holding the banknote up to a light source, which makes the security thread visible as a continuous dark line or stripe embedded within the paper.^[46]^[47] In denominations like the U.S. $20 bill, the thread appears vertically to the left of the portrait and bears repeated microprinted text such as "USA TWENTY" with a small flag in an alternating pattern along its length.^[46] For euro banknotes, the thread shows the denomination: for €5 and €10, the € symbol and value in tiny letters; for €20 and higher, "EURO" and the value in tiny letters, when viewed against light.^[47] Windowed security threads, common in some modern designs, expose segments of the thread at intervals along the note's edge, allowing direct observation without backlighting.^[1] Tactile examination involves gently feeling the surface and edges of the banknote to detect the subtle texture or raised elements associated with the embedded thread, which integrates seamlessly into the paper without creating bulges or separations typical of fakes.^[48] Tilting the note under light can reveal dynamic effects in advanced security threads, such as color shifts from iridescent or holographic materials that produce motion or metallic sheen, enhancing authentication for features like those in certain international currencies.^[49] Under ultraviolet (UV) light, genuine security threads often exhibit fluorescence, glowing in specific colors that vary by currency and denomination.^[1] For U.S. banknotes, the thread on the $10 bill glows orange, while the $100 bill's thread emits a pink hue, confirming authenticity when exposed to UV.^[50] In euro banknotes, UV exposure highlights fluorescent elements, including green-glowing components in security features like embedded fibers near the thread, aiding verification.^[51] Magnification tools, such as a jeweler's loupe, allow close inspection of microprinting on the security thread, which appears as fine, legible text under 10x or higher magnification.^[52] On U.S. dollar threads, phrases like "THE UNITED STATES OF AMERICA" are repeated in tiny script, blurring into solid lines on counterfeits due to printing limitations.^[3] This method verifies the precision of the thread's inscription, a hallmark of legitimate production.^[1]

Impact on Counterfeiting Prevention

The introduction of security threads in U.S. banknotes during the Series 1990 redesign correlated with a significant long-term decline in counterfeiting rates, particularly for higher denominations. For instance, the incidence of counterfeit $100 bills has dropped by over 85% since the 1990s, attributed in part to the thread's role as a visible deterrent that complicates replication for casual and mid-level forgers.^[38] Similarly, in the eurozone, following the 2002 launch of euro banknotes featuring embedded security threads, counterfeiting peaked at around 594,000 detected fakes in 2004 and rose to approximately 666,000 by 2008 before declining in subsequent years. As of 2024, detected euro counterfeits remain low at 18 per million genuine banknotes.^[53]^[54]^[55] Security threads function as a core component of layered security systems in modern banknotes, classified as Level 1 features that enable public verification through simple tactile and visual checks. According to standards adopted by central banks, such as those outlined by the European Central Bank and the U.S. Bureau of Engraving and Printing, Level 1 elements like threads complement other overt features, including watermarks and color-shifting inks, to create multiple barriers against forgery without requiring specialized equipment.^[56] This synergy enhances overall deterrence, as no single feature can be perfectly replicated, forcing counterfeiters to overcome interconnected challenges.^[57] Despite their effectiveness, security threads have vulnerabilities that sophisticated counterfeiters exploit, particularly through high-end digital scanners and printers that attempt to mimic the thread's metallic or holographic properties. Early embedded threads could be simulated via printed lines or pasted strips, prompting upgrades to dynamic motion threads—introduced in various currencies around 2010—to incorporate tilt-activated color shifts that evade static scanning techniques.^[9] These countermeasures have sustained the threads' utility, though ongoing advancements in digital forgery continue to necessitate iterative improvements.^[58] Looking ahead, security threads are evolving toward integration with smart technologies, such as RFID chips embedded within the substrate, to enable machine-readable authentication in future banknotes.^[59] Such innovations aim to address rising digital threats, ensuring threads remain a foundational element in global anti-counterfeiting strategies.^[60]

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