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It sounds like the file path for your swatch tables is wrong. Flexi is looking for a swatch table on a folder that either doesn't exist or doesn't contain the swatch table(s). I don't have Flexi on this machine. So, I'm going from memory here. But you should be able to go to View>Open Swatch...

Make sure the banner is dry, and make sure there are no "slugs" filling up the die prior to piercing.

The dots of ink at the left side of the photo are likely caused by a piece of fuzz (often from scrim banner material) on the printhead(s) that is wicking ink and depositing it in droplets when the carriage stops and moves back to the right. The large smudges in the printed portions look like...

One of the finest voices in country music.

Nice. MikePro has it dialed in. It's all about what works for you.

Your reds are largely dependent on your profile and ink. That being said, I've gotten great results with 0/100/100/0 on a few different machines. You can back off the yellow in small increments if it appears too orange. Sometimes, adding a bit of cyan can take away the orange hue as well.

Sirius Jam On at the shop.

One of my favorite television series of all times. I have a friend named Clarence that I nicknamed Lumpy years ago.

Try Separating the Outline from text. Then, select both objects, and weld them. Also, what type of outline are you adding? In this case, you want to use an outline "With Backing".

Jumped the shark is a Happy Days reference. Mork and Mindy is a Happy Days spinoff. It all comes full-circle.

That is how I'm familiar with him, too. The babies from Ork were born old (to the males) and got younger every year, right?

Flexi won't open a .tif with an Alpha Channel. Flatten the file, import the resulting raster image and create your cut line in Flexi. You may be able to export an acceptable vector cut path from Photoshop (Export Paths to Illustrator). Flexi doesn't work well with transparent bitmaps--even those...

I've never had luck with Flexi supporting transparencies. It even has issues with proprietary transparent effects created within Flexi.

Yes, I also would check the encoder strip.

I would guess that the offending tiff contains an Alpha Layer(s). Open in Photoshop, remove or flatten offending layers and resave.

2 cups of black coffee in the morning.

The file likely wasn't createdy with so many masks--that's just the way FlexiSign parses or interprets a non-native file. Illustrator files are notorious for this. For instance, Flexi will interpret a vector gradient from Illy as hundreds of individual rectangles with a mask around it...

Yep.

If I understand the OP, he imported a vector template into PS and added some effects to it. Why not import the saem vector template into Flexi to use as a cutline rather than use the magic wand or transparent bitmap/contour cut feature in Flexi which both rely on imperfect raster data to create...

Import the flattened Photoshop document into Flexi. Import the original vector template into Flexi, align it with the raster image and convert the vector template to a contour cut.