Theres a routine I learned from Magick Balay (is that his name?) that uses a prediction card. It starts off half sticking out of his pocket so that only a corner is showing.
Card is picked, you show your prediction which says "look at the top card", the top card says "look at the other side of the prediction", which says "look back down at the card", which has changed to the selection. Nothing special but I just love the way this routine works.
Anyhow, what I think you are missing is the fact that you are using a PVC card. If you are going to be using it as a regular printed prediction, why not just use a normal index card or blank playing card? How does using a PVC card allow you to perform things you normally wouldnt?
So how are they special?:
-Hard PVC: durable, probably cracks, can melt
-Wallet sized: can carry everywhere, not poker sized, still able to palm and what not
-Customizable image on both sides: able to imitate other PVC cards, can be a late reveal
One of the ideas which immediately comes to mind is photocopy a PVC card you already own or the people around you do: school ID, ID card, Drivers License, Membership Card, Credit Card, etc. Photoshop the photocopy to... be a reveal or anything else. From here you can have a built in prediction or card change. W
hat about rubbing the face your ID card and changing it?
Taking to cards and morphing it into one. sort of like half a library card and half a credit card.
How bout starting with a blank PVC and using it as a "copier", sort of like Daryl's Presto Printo but with one blank card and your own wallet cards?
You could easily use this for a variation on Daniel Garcia's Fraud but with... a word or image on you library card.
How bout using Homer Liwag's All fogged up idea but with a drivers license?
"License and registration please"
*hands over blank card*
"whats this?"
"my drivers license" *performs trick*
"im arresting you"
"S**T!
You could also use the card as a form of producing something. Print a coin, bill, gum what ever on one side and leave the other side blank. Show both sides blank, take a coin and "rub" it into the card. Show it around. Rip it back out. Show both sides blank.
This sounds like a fun way to give out business cards. Print an image of your business card folded into quarters on one side. When someone asks for it, give them that card. They look at it confused. Apologize and dump out your real business card folded in quarters. Show both sides blank... An extra idea just for the kicks would be... when your client or who ever looks confused, take out a dry erase marker and say "oh sorry. the printers got it wrong. that word is meant to be... Jeffrey (or what ever)" and you correct it on the PVC card. So what they end up with is still quite a useless object. You then apologize and dump out the card, which has the same correction on it. You can do that with their initials, your email, anything. Sorry if this sounds confusing.
How about... a variation on Joshua Jay's Cash Credit. Show them your New "credit card" which could be some self-designed card that says... "$20.50" or what ever. Explain its a new form of payment which keeps neater and doesnt crumple or rip. You then perform Cash Credit, turning it into a 20 dollar bill, then do the classic coin from rolled up bill for that extra 50 cent kicker.
How bout a semi voodoo effect? Print a spoon or pen or what ever on the card. Show the actual object, ask someone to hold it tightly. Now use a flame and melt the card so its malleable. Twist it, bend it, crack it, what ever you want. Do the whole "and you may feel it getting warmer and warmer until it almost hurts." blah blah blah. Hopefully, if you're good enough, they fall for it and feel the pain, they flinch and drop it or open they hand, revealing the object's transformation. This may be a tad expensive... considering you said $10 a card... but just throwing it out there.
Its getting late here (3 AM), so... I'll spit out one last idea...
How about... for the mentalist sort of approach... print some symbol or arrow or word on it. Some form of a modern Ouji Board thing. Ask it a question and it flips to either side Yes or side No. Spread the cards on the table and it slowly points its printed arrow to their card. Ask a really general question about people... "who has been having family problems recently which has been extremely hard on them?"(or what ever) more or less making a cold reading statement into a question and perform Matt Sconce's Spin with it. No matter who it points to, the question should still be viable.
Anyhow, thats my input for... a good 24.76 minutes of thinking. The sky is the limit.