Summa D140 - Irregular Cutting

I've been having much success with doing full cut out stickers on my summa with a 2-pass setup. I've cut a few thousand and have had minimal problems. I had to change my blade, and got it back to where it needed to be and it was cutting good but I go to cut these squares with rounded corners and for some reason it has a really hard time cutting through every side...I'd say 60% tear the backing because the cut isn't deep enough...if I go an cut a different shape or more complex it cuts fine....this is driving me nuts. I can't seem to get these to work smoothly no matter what I do.

 

2 kiss cuts.
I had cut a bunch of lightning bolt shapes a day before and they came out nice and clean.

 

I changed my cutting strip this morning to see if that would resolve my issue and it did not make much difference at all.

I'm just beating my brains out trying to understand why I can cut a complex shape with no issues but a circle or square is the hardest thing for it to do.

The only thing I can possibly think of is that it's something to do with my laminator. The outer edges of the rollers don't have quite the same pressure as the center...which is also strange in itself as rollers wear the opposite way from what I've seen.

And the outer edges are the spots where I'm having the most difficulty cutting.

 

I don't think I'll ever understand why this cutter cuts the way it does.

Squares are difficult for it to cut...Top, bottom and right of the stickers are cut fine but the left side never cuts as deep as the other 3 sides. Even when I do the pressure test the left side of the square is always not cut as deep.

I wish someone could give me some help....this still doesn't make any sense to me why it does this. Is it a blade holder issue? A cutting head issue...? This is so frustrating to have bought something that is sold as one of the best cutter brands and yet has problems cutting a simple square.

 

I cannot add any more pinch rollers to the model i have. It's not an option on the base models.

 

I'm not doing Flexcuts but it it pushing to cut that side. Guessing that is the issue? that it's pushing the cut instead of pulling it.

 

Maybe if the start point was different possibly? Not really sure what determines the start points in the cut path.
Yeah I've got no issues with complex shapes. Maybe I'll try doing 45 deg as I've got to reprint some of them.

I think I know what you mean...in that last part...just having an extra cut line on that side if I'm understanding you correctly.
Right now I've got two rounded corner square cuts on top of each other and for 99% of stuff it works great except circles and squares it seems to have difficulties with.