I am trying to get a response if anyone mails unsolicited debit cards to their customers. I am trying to see all risks and issues that may come with this type of mailing.

REG E states certain requirements which would be met. What other areas should I review for mailing?

If your customer has moved and there is someone else at his old address, you could have a mess on your hands if the card can be used with only a signature prior to activation.

I know when I teach Reg E and poll bankers, few, very few, send unsolicited cards.