From what I've heard there's only one company that pays the USPCC enough to guarantee that every card is exactly the same, border-wise. For everyone else there's bound to be some variation in the borders, some more noticeable than others. It's really not a big deal.
Hey Christopher, this is actually not correct. If there was a company that did that, it'd be theory11, but there isn't, and it's not (verified with USPC directly this morning). USPC has very specialized machinery that enables a very precise cut on 99.9% of decks, but there's no way to guarantee a perfect cut every time.
On normal border decks, the difference in width is very difficult to perceive. With our super-thin borders, that same variation can be slightly more apparent. In any event, USPC has done a great job getting borders precise, such that mis-cut decks are rarer than ever, and any alignment imperfections (like the picture above) are often
extremely subtle.