This is an awesome write-up! I've run into the same issue trying to print QR and PDF417 barcodes on cards printed with the various Zebra ZXP printers I've got for testing with ConCat, but the same as you found, PDF417 appears to be far more reliable with the differing quality between each print.
this post was submitted on 03 Jun 2023
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what a fun blog to read around in! well done