Card arrived bent — what I tried
Oof, that's rough. If the barcode is dead or damaged beyond the crease, there's not much you can do. Before tossing it, I'd check if it throws a red flag on Intellicheck or similar scanners — sometimes the PDF417 string format can still parse the data once you flatten it out. Lay it under a heavy book overnight, but expect it might still have issues on strict verifiers if it scans as under 21 due to positioning errors.
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A package containing a fake id was delivered bent from transit pressure. Not a sharp crease, but a visible and tactile curve across the diagonal. Tried a few things before settling on what actually works.
What caused it
The package had been compressed at some point during transit. The novelty id arrived in a standard envelope with cardboard backing, but the envelope itself had been folded slightly at a corner, and the pressure had transferred to the card inside. Not a vendor packaging failure specifically — the packaging was adequate, the transit handling was just rough.
First attempt: weight press
Placed the card flat on a hard surface with heavy books on top for 48 hours. This reduced the curve slightly but did not eliminate it. The card was less warped but still noticeably curved when viewed edge-on.
Second attempt: gentle heat
Researched whether heat helps with polycarbonate cards. The answer is yes, carefully. Polycarbonate softens at temperatures around 140°C but begins to flex at much lower temperatures. I placed the card between two sheets of parchment paper and set a clothes iron to its lowest setting, then pressed for about five seconds at a time, alternating sides, with books for weight immediately after each press while the card cooled.
After four cycles, the card was essentially flat. Let it cool fully under weight before using it. Total time was about 30 minutes.
Important cautions
Do not overheat a card. Extended direct iron contact will damage the surface printing and potentially the holographic overlay. Five-second intervals with immediate cooling under weight is the safe approach. If the scannable id is severely bent with a sharp crease, heat will not recover it and you need a replacement from the vendor. Contact them with photos before attempting any heat correction — a crease that goes through the holo overlay may warrant a replacement claim even if you can flatten the physical card.