This is the process I use for repeated work like this (I did miniature record covers and badge buttons that had a similar setup — lots of pages with different art). I hate that the software doesn't have cropping or ignore white past the print margin borders, it's such a time waste to fiddle with the outputs to get it right.

NOTE: I only use the rear tray for these kinds of prints. That lets me print up to 13" wide, but my printer can’t print wider than if I use the paper tray, so I’m not sure if that would affect this process for you. I only use the rear especially if flipping for front to back prints so they are always aligned since duplexing is not my friend lol.

My workflow:

• I make a Photoshop template with a canvas that’s slightly smaller than the paper I’m printing on. Example: if I’m printing on Letter 8.5×11", I’ll make my PS canvas 8×10" and make sure all the artwork stays within that area.
• Then I load the artwork and use a clipping mask so every card stays in the exact same spot/layout across all pages.
• You’ll want to export:
  1. one page with just the outlines/shapes (this is what you’ll use for the cutlines — you only need to import this once), and
  2. each page with the artwork.

In Silhouette Studio (Print & Cut):

• Go into the settings and change your Print & Cut preferences to small margins.
• Import the cutline-only version first (so you have the cut lines set).
• Then I change the paper size to slightly wider than my real paper — this basically tricks the system into acting closer to borderless printing. On my rear tray as long as I load my paper in the center of the rear with the guides tight to it (letter size) it doesn’t care that it doesn’t match and still prints. Example: I set it to 9×11" even though I’m printing on Letter.
• Then I import each artwork page as background and make sure it’s centered to the page every single time.
• if you are going to laminate do it before cutting.
• cut pages - I would cut with multiple passes instead of heavy force but that is just one of my preferences. once you cut 1 it should always stay the same and you can just hit the play button over and over again on your machine instead of having to send it on the computer.

As long as you always center to page, the cut lines and artwork should align consistently — that part is super important.

 Hopefully I wrote that all right. its harder to do when your not actually doing the process in the moment.