I think that only happens if the chip goes bad on its own... not via the "microwave oven" method. :)

Unfortunately free replacements after the first year are issued for the number of years remaining the original. When I had mine replaced I did get an extra 10 months though because the expiration date is x years from the reissue date.

I my case, my passport card just started to fall apart after carrying it in my wallet for 7 years. They can argue that it is an abnormal "wear and tear" and thus refuse to issue a replacement for free, but it's still worth a try.

I am no fan of tinfoil hats, so I wouldn't microwave my documents anyway ;)

I see. Well, I can wait until its 2 years + 1 day to send it in :) I don't know if they will change the passport card design as well in 2018, so I am a bit hesitant to renew it and be stuck with the old design for another 10 years (if free replacement is not possible in my case). What if they decide to include a signature in the passport card (making it fully-compliant with ICAO standards) and allow flying with it? I know it's wishful thinking but still...

I think it really depends on the person that you speak to. I remember the lady that I talked to said she was at the passport agency facility in South Carolina. She was really nice over the phone.

Mine was pristine at 8 years in my wallet when I replaced it at the same time as my PP book.

But I also kept it in the included paper sleeve.

The passport card without the signature is ridiculous. I have no idea which hairbrain came up with this.

Mine sits in the sleeve in my wallet and I barely take it out. I find it a waste, and I will likely refrain from getting a new one, though if I do get it, it will be maybe a couple of years after my passport is issued in order to have valid proof of citizenship at all times.

I am trying to naturalize in an EU country, and if that works (only if my request for an exception to renouncing US citizenship is accepted, of course) I will also have an EU passport. In this case, it would be GREAT if the passport card is accepted as a travel document for air for dual citizens at least, which may eventually only be possible with a signature. Otherwise, the card is seriously of very little utility abroad, even tough it is often accepted as official US ID when picking up packages or entering official buildings.

I never sign my passport books. :) Not my current one or the one before it. I've only gotten one remark from a French immigration officer maybe 5 years ago. (went to France on the Eurostar) He said(in perfect American-accent English): "Haven't you ever had troubles traveling with an unsigned passport?" I just told him that I would sign it when I get to my hotel.

I carry my passport card next to a bank card almost everywhere I go. I've had no problem with the durability of my passport card. My passports are a bit of a different story.

Have you tried to clear passport control in Germany? They refuse capable US adults from using US passports to enter Schengen there unless they are signed.

I cross land borders on a regular basis, and on a very frequent basis, need a quick way to prove citizenship when someone decides they don't know me well enough to share ITAR/EAR info with me and/or to get on federal facilities on the odd chance I don't have my PIV-II badge on me.

Yes... last 4 entries/departures at FRA. (according to my MileagePlus account) 12/23/2016, 12/17/2016, 5/31/2016, 5/22/2016. Also encountered German border officers when enter Germany from Denmark last summer. Not really why they were on the train.... probably just a random spot check?(first time I've encountered one within Schegen zone)

as for the passport card, I also keep it in my wallet at all times.... even after 2 tours in the washing machine, it survived just fine after almost 9 years. (the leather wallet didn't survive :( )

You're saying the German passport control to enter Schengen at FRA has repeatedly accepted and stamped for entry your unsigned US passport within the last 12 months?

I dislike entering Schengen at FRA. (almost alway flying from ORD, EWR, or MIA) They only stamp my passport half the time. I usually fly into Amsterdam and success rate of getting my passport stamped has remained 100%. ^ speaking of passports, I always present my US passport card when checking into hotels in Europe. Success rate there is about 90%. (with the 10% being okay with it, after explaining to them what a passport card is)

Try taking the train from CZ to Dresden. The Polizei board the train nearly every time and have for years.

My 18 year old Niece had issues from returning from a closed loop cruise because she forgot to sign her passport. CBP officer made big stink about it asking for two other proofs of signature.
She didn't have any credit cards just her license. I think she found a college ID after awhile I was already thru the line wondering what was taking so long.