Card Jams and Feed Errors: Roller, Sensor, and Debris Causes
Persistent feed errors usually mean worn rollers, a contaminated card path, or a misaligned sensor.
Worn feed rollers
Rubber feed rollers harden and glaze over time. Cleaning may restore grip temporarily, but rollers older than 2–3 years on a high-volume printer should be replaced.
Card path debris
Card chips, broken card fragments, and adhesive from holographic overlays accumulate in the card path. A full path inspection and clean usually resolves intermittent jams.
Sensor misalignment
Card-position sensors that drift out of alignment cause the printer to think there's no card present, or jam mid-print. Sensor recalibration is part of every full service.
Card stock
Off-spec card thickness or warped card stock will jam even a healthy printer. Use OEM or Composite PVC cards rated for your printer.
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