Best I can tell from my case tracking, the NSC ceased ordering the physical cards on June 15, 2005. The last one of which was mailed June 25th. Prior to June 15, there were card orders pretty much every business day, after that nothing.
I suspect, but have no way of knowing, that this is somehow connected, to the worldwide suspension of approvals of I-485s (see http://www.murthy.com/news/n_jul05a.html ). As far as I know the suspension of approvals should in theory have no effect on the ordering of cards for cases that had already been approved. But in the USCIS/NSC delays are the norm ....
I suspect, but have no way of knowing, that this is somehow connected, to the worldwide suspension of approvals of I-485s (see http://www.murthy.com/news/n_jul05a.html ). As far as I know the suspension of approvals should in theory have no effect on the ordering of cards for cases that had already been approved. But in the USCIS/NSC delays are the norm ....