Visit the U.S. Department of State Passport Card web page for a description of the card, its uses and the application process including fees and processing times.
Download a passport card application form from the U.S. State Department website. If you were issued a U.S. passport within the previous 15 years at an age of 16 or older, are in possession of that passport and the name on the passport matches yours or you have proof of a legal name change since its issuance, you are eligible to apply for your passport card by mail and may use form DS-82.
If you have never had a passport or have a passport which was issued when you were under age 16 or are currently under 16, were issued a passport over 15 years ago, have had your passport lost or stolen or your name has been changed since your passport was issued and you do not have legal proof, you must use for DS-11 and apply in person at an Acceptance Facility or Passport Agency.
Complete the appropriate form. Gather all the required documents to submit with your Passport Card application. If you are using form DS-11 you will require proof of U.S. citizenship with photocopy, current photo ID with photocopy, one passport photo and the applicable passport fees in the form of credit card, check or money order. If you are using form DS-82 you will require one passport photo, your latest passport book or card and the applicable passport fees.
Mail your DS-82 Passport Card application to the address printed on page 2 of the form. If you are using a DS-11, you must appear in person at an Acceptance Facility or a National Passport Agency to submit the application.
Choose between standard and expedited service based on your time constraints and financial considerations. Standard service costs $30 and your Passport Card will arrive within 4-6 weeks. Expedited service costs $90 to ensure delivery of your card within 2-3 weeks, as of April, 2011. If you are using form DS-11, there is an additional $25 charge for either method of delivery service.