cutter is shifting cut lines

It looks like you have the the multiple registration marks setup and it stops at the middle set, is that right?
I never managed to get cut files sent out of onyx to our 8600, but I figured out how to do it with just corel, cutting master 3, and exporting reg marks myself.
I don't mean to be 'that guy', but couldn't you just cut these by hand pretty quickly, or do you have a whole mess of them to do? I've never thought to run banner material through the plotter...

 

Vinyl cutters are not meant to cut banner.

 

That makes sense. So basically you need to use the perf cut option. The cutter needs there to be some dimensional stability when it's cutting or else it will do what is happening in your photos. Perf cut leaves parts uncut so that the paper doesn't crumple up during cutting and then you just pop them out. You might have little chads around the edges though.

 

Perf cut cuts all the way through for about 3/4" and then lifts the blade so that it doesn't cut for about a few millimeters and then lowers down again to cut through again and so on and so on. This leave little bits still attached to the paper so that the material doesn't crumple up during cutting. If you are just cutting through on standard mode, it will always cut off eventually because the paper becomes unstable. There should be something in the manual about setting up a perf cut properly.

 

Is this the first time you’ve tried this? A roll to roll cutter will not handle something like this well at all! Even with perf cut you’ll tear through your cutting strip

 

If you are running corel and cutting master 3, you can specify the order and start position and direction of travel for the cut. I have done a run where I needed to cut out 2,000 stickers, so I needed to perf cut, but did not have the blade attachment, so I tediously layered, sorted, and spaced everything so that as it fed through the plotter, it would only cut vertical lines until the end, at which point it would slice all of the stickers together with one cut, going the direction I wanted it to. You could try something like that, or you could cut through it part way and tear it free?

 

So, you're making paper banners, so to speak............

Very seldom do we cut a paper product on any of our machines, unless there is a backer, to prevent this problem you are describing. All paper banners, signs or whatever...... regardless of size or how many are cut by hand or some sorta paper cutter meant for this purpose. Your boss may have wanted to save money/time by using this method, but he didn't do his homework properly. Wanting to do something and only having partial information does not mean it's gonna work without a lotta time, headaches and lost money.

If you have a hundred or two of these and you don't have the proper equipment, you'll need to get a cutter of whatever size required and start cutting. A hundred or two, shouldn't take more than maybe 2 or 3 hours. How many hours have you wasted trying to figure out something which is not meant to be done, already ?? It looks like you have over 24 hours in it already and you're not any further, than yesterday morning. Just start printing and get somebody cutting. Besides, it'll build muscles, so you're doing two things at once. Making money while exercising.

 

I might be preaching to the choir, but the choir doesn't seem to be singing today. You need to illustrate to your boss what's going on, by showing him his loss in time, wrong equipment and explain to him what is happening and it's not really gonna get any better without getting either proper equipment or giving in to his mistake(s) and rectifying it from one point or another.. You'll need to show him on paper, not explain it. It sounds like your boss is the kinda person who reads things and then makes decisions haphazardly. He does not listen to verbal instructions or explanations very well, or he wouldn't be trying to make things work in situations where they simply cannot.

I'll bet ya a donut, when he bought this, the salesperson never said it would cut paper like you want it to. He only heard what he wanted to hear and put the rest of the story together himself.