After playing a crucial role in the development and industrialisation of polymer banknote substrate in the 1980s, Note Printing Australia (NPA) has printed polymer banknotes exclusively for the last over 30 years. In that time, NPA’s design and technical experts have worked continuously on improving its process to the point of making informed decisions about issues such as optimal security hierarchy, family wide designs to suit circulation conditions, and design for manufacture without having to compromise on aesthetics. This presentation provides key insights into the critical thinking at NPA, which can result in significant savings during the manufacture and life cycle of polymer banknotes.