Hey Angela, Although I didn't do passport invites myself, I have helped other brides create their templates, and as far as I know, their test prints have printed okay. What program did you use? did you double check your margins? Did you turn on your gird to verify alignment? When you choose double sided printing are you printing along the short edge or the long edge? An easy fix (dependent on your design) might be to extend the image area in both directions by and 1/8" or so to compensate for the misalignment which will give you some play when you cut out the invites - Does that make sense? Let me know if any of this helps, I'm sure there's away to get this right without re-inventing the wheel.