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Could be as mentioned above, however, just based on those photos you attached, that pretty good prints for the SP-540V, I've seen my SP-300V's do much worse. I'd do a nozzle test to see how the heads look.

I assume he was talking about the metal wire that the cutting carriage is attached to.

Also, as this is more of a sign based forum, you might get better answers going to printplanet, where their forum is more based on that kind of printing.

The Oracal line is usually pretty good.

Based on that nozzle test, you have a lot of deflection on the black, my guess is that you had a head strike at some point. My suggestion is get a new head.

I also noticed with the TR2 inks, you are more limited to the medias you can print on, have you tried a matte material, as I find, myself, having more issues with glossy materials on my SG-300. You can play around with the profiles, one of the profiles I find gives you the best quality on glossy...

What cling of media is it? from the photos it looks like maybe a static cling? Anyway, I'd play around with heat. Are you sure it's the heater that is bad, depending what printer you have, it could be something else. I had an issue with one of my Roland SP-300V's, where it wasn't heating up...

Back to the OP, what media are you using, as we have a SG-300, the previous version and have noticed with the TR2 inks, they don't bond nearly as well as the previous TR inks.

It effects the Eco-Solvent printers, typically when you print on it when it's gone really bad, it doesn't print as well and the media shows either textured lines or spots, kind of what it looks like in the photos you sent. Do you know how old that media is?

What printer and media are you using? Also, are you using the appropriate profile for this media, looks like it's not putting down smooth over the textured media, might either need more heat or less ink based on the look.

What printer are you using?

There is also Oracal's 3651G, we've used it in the pass, and it was pretty good.

From those photos, if I am reading it correctly, it's printing off as it goes down the sheet, not the cutting, correct? (I don't see any cut line around those last 2 images) If that's the case, I'd look at your art file, as if it's all one file, then it's shouldn't be able to drift as it prints.

Sent you a PM, feel free to reach out email: artwork@zoogee.com

That 16 mil, was the specs of the machine in the most ideal situation, so the little over 12 mil, just might be too much for it to handle.

I know, they sell that machine like it's the bee's knee's, but it's not, needs much improvement, the only benefit it really offers, is that it's more compact. It doesn't even have a heater, so for sticker businesses, that's a big downer.

they might have something in a permanent, might be worth you taking a look. But in the meantime I'd try that 3mil stuff you have to see if the printer cuts through it, just to confirm my suspicions.

Not sure if you need permanent or repositionable, but we use a 6mil Repositionable media from Oracal their 3268M and it's backer isn't all that thick.

I hate to tell you this, but you probably bought the wrong machine for the job. From my experience and I am a little bias, but the BN-20 is a waste of money, you would get better bang for your buck buying a used larger older model like a VS-300i or SP-300i.

I think you just answered your own question right there. If it says semi-rigid anything, then you know it's fairly thick stuff. Have you tried a thinner media just to see if that works. My guess now that you've said that, is that the media is too thick for that printer to cut through.