I had some problems getting my Silhouette vinyl cutter to recognize the registration marks on the black screen-printed layer of the shiny Dura-lar. Apparently, the surface of the Dura-lar was too reflective for the cutter to recognize. I have had a few other complains about the Silhouette as well, so I decided it was finally time to upgrade to a professional vinyl cutter. I ordered the US Cutter Titan 3 in the small craft/hobby size after seeing some good reviews of the larger version of that model. In addition to generally using much better components (it has an almost silent servo motor rather than a stepper), it has a vacuum hold-down feature and, most importantly, manual laser alignment in additional to optical registration mark recognition (which hopefully works better than the basically worthless optical reader on my Silhouette). This means even if the optical recognition on the cutter doesn't recognize the registration marks due to the Dura-lar reflectivity, I'll be able to manually register the cutter with my prints using the laser.
I may get another black screen burned with the new registration mark style required by this cutter. Coincidentally, I was contacted today by an owner of one of the original Mark VI tricorders who informed me that, for the record, the black around the screen is printed on top of the gray, presumably as part of the screen-printed black ink. So that will be an advantage of getting the black screen re-burned. It'll allow me to add the screen border as well.
The cutter arrived today and it is working great on vinyl, but I haven't yet been able to experiment with print-and-cut. I'll tackle that tomorrow probably.
Anyway, just a minor update, but that's where I am.