Thanks for all the feedback - exactly what I was looking for!
Going to go through and reply to a few points:
- This wouldn’t be a replacement to the instant issuance of virtual cards via a digital wallet - having that would severely reduce the demand for expedited delivery, but it’s still a different issue
- Users wouldn’t be charged extra for the nameless card, they would be paying for the quicker delivery. We would still have a stock of these at the office like we do now for people to collect
- “Next day” is referring to a tracked next day service, while first class tends to get there next day (93% of cases according to Royal Mail) there isn’t any guarantee. I suppose a different option is to offer the choice of named vs nameless cards - one would go via a manufacturer and take 3 days, the other would be sent same day first class like it is now. It generally seemed that people want names on the cards so the ‘standard’ would still be via the factory
- The option of getting a machine to personalise cards is in the early stages of exploration right now, I went to a visit the Head Architect of Metro Bank with Tom a couple of weeks ago to discuss how they did it - that would be the dream and solve a lot of this! It’s high risk to launch the bank on however so going with a third party is what we’re doing now
- Having a second card is a great option, the only issue is that it would immediately double card costs overnight (unless we charge for the second card, really don’t want to have lots of little charges in our offering as it detracts for much from the experience) - this hasn’t been excluded but that’s a reason why I’m looking at a few different options and ideas to basically solve the higher level problem of "What happens when a user loses their card, and how do the different situations/users change the need for different levels of service?
- We wouldn’t be using this as a revenue stream - the prices I picked were for simplicity and I didn’t really want to get into a discussion of £5.50 vs £7 etc. There is a request of us to expedite cards, or offer two cards, I was interested to see if this was still there as much and how people felt when the cost of this service was passed onto the user.
Bit of a brain dump but I hope it gives you a bit of insight into the thinking around this 
Cheers,
Anthony