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If it's going to be printed in sheets use what image you have and don't worry about res. Scale it to the needed size and then make your print sections with overlap etc. Export as tif using LZW compression 150dpi max.
Yeah, good luck with that. We tell 'em you can get 'em a whole lot cheaper than we can produce them. Once they nail the template they can produce 1000's as a perfect fit and they sit on a shelf for quick distrubutiion. We'd have to do a lot test prints to even get close. Not worth the trouble.
Does it fail on the very first reg mark or goes around finds each then fails at the last one?
Fails on a large print (more than 10ft) or fails on any size?
Watch the edge of the material is it "walking" a good distance (more than 1/4")?
"re-business" might be in order if you can't decipher the guidelines. Import the page you need, change the text, move things about and proof for approval. Yeah, complicated.
It does sound like that sensor/camera has gone bad or possibly have a piece of vinyl stuck on it. I'd study how to remove that whole head just enough to view the underside.
What about your layer structure. We print to an HP latex and cut via a mimaki plotter with FineCut. All the reg marks, layers, etc are set up in corel first. Are your marks on the correct layer?
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