Most card jams in a badge printer are the result of too much static electricity buildup between the PVC cards.  The static electricity causes the cards to stick together and when the badge printer takes a card from the card hopper it will inadvertently take two, which causes a jam and an annoying noise from the printer.

To reduce this make sure to individually separate each card before you stick them in the card hopper.  This takes extra time but you will be rewarded with less card jams and wasted materials.  It is important when separating each PVC card to handle them by the sides and not the area being printed on.