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Did you try doing an OPOS calibration?

Another option to consider is making your prints narrower. I regularly print on 54" 6 mil media, with a 10 mil laminate that is 51" wide, I try to keep my prints less than 46" wide and this is WITH the extra pinch roller. You can also place the leftmost pinch roller inside(to the right of)...

It's probably fine with small pieces or one-offs, but on large pieces, it will separate the silicon layer from the paper underneath it anywhere the backer has been stressed in the slightest. But it works very well with air egress films, which is what it was designed for.

510U works very well for air-release films, definitely don't use it with non-air-release however, unless you want to get rid of a customer.

High Performance Photographic Resin Latex Imaging Capable of print resolutions up to 1,200 x 1,200 dpi True 600 dpi per color channel per single print pass Enhanced Variable Droplet Technology as small as 4.2 picoliter Unique coating technology reduces the likelihood of a print head clog on...

The Colorado series is outstanding for banner materials. The speed, quality, and durability are top notch, and you can cut it off the printer and throw it directly on the table for finishing with zero worries.

Using the black nose piece should help, and set cutter to the slowest speed you can tolerate. If you are cutting thicker lams on the regular I would highly suggest adding another pinch roller, Summa calls it a "media select kit" for some reason. It will pay for itself within a year...

I swear that photo was taken at Mar-a-lago, probably Don Jr.'s daily driver.

Oracal 820 is a "tamper-evident" vinyl that should fill your requirements.

You can use third-party file sync software to copy your cut file folder over the network to another PC at regular intervals.

3M VHB tape comes in many flavors depending on what you must adhere to. Rapid Remover takes care of any glue that I have encountered.

https://www.allfrom1supply.com/VS1000-Surface-Cleaning-Solvent-1-Gallon https://www.johnsonautobodysupply.com/axalta-vs1000-surface-cleaning-solvent-gallon.html

Polyester is the way to go. You may need a UV or latex printer to print on it though

I saw this quote a few years ago and it struck me how accurately it explains the current world we live in. “The problem with the world is that the intelligent people are full of doubts, while the stupid ones are full of confidence.” ― Charles Bukowski

Another thing to try....your leftmost pinch roller can be placed inside of your crop marks and this can lead to better material stability as it feeds back and forth and therefore better accuracy.

Have you tried putting Scotch tape on the crop marks? I've only ever had to use it on chrome and reflective and it works most of the time.

If you have a full version of Flexi, try playing with Bezier, this will convert the image to vector and make it easier to clean up - also try enhanced corners and enhanced curves.

www.signburst.com..... the Inferno series should handle whatever you need it to do, and the tech support is the best I've seen anywhere.

No, not yet. Bill Gates is working on a literal Skynet....https://en.wikipedia.org/wiki/EarthNow

GF Motomark 235 will stick to it, and I'm fairly certain that Avery 2126HT would work also.