Its very important that both rollers mesh perfectly to get a good impression. if they are misaligned even a little it wont make a deep impression. Usually I assemble the gears and the rollers together and slip both rollers in together at the same time to make sure they stay meshed and don’t misalign while installing them into the housing. Also try flipping the rollers as well. Some papers do work better than others, in the photos Im using 300 GSM card stock which is pretty thick. Ive also tried 284 GSM card stock too. Make sure as you crank that the housing isn’t separating either.

Yes the alignment is very important but that is the issue. After printing it it does not align perfectly in any orientation. If you roll it slowly you can feel it jump over the sides of the face for example but there are other issues too.

Are you printing in sport or ludicrous mode or maybe using a temp on the high side that you may be getting filament expansion or slumping? here they are meshed and held up to the light. They mesh in all 5 faces.