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We can fly to Canada twice even if we are called to fetch our PR cards as long as our status is maintained.

Our only concern is that if ever there is risk of any interview for physically collecting the cards, AND if my spouse’s explanation isn’t convincing to the immigration officer, then is it that we will be issued a departure order and in that case it might hamper my chances of sponsoring spouse again? Since spouse gets a departure order, she will have to run behind certificate of departure given by CBSA. I don’t know how that works and it will be too much of immigration stuff to deal with in addition to the already piling problems.

So my concern will be is travelling to Canada before expiration of cards and put in a new application for renewal a better choice OR I’ll just wait for cards to expire and apply for a stricter process i.e PRTD. Even If they reject PRTD there will be no departure order because we wont be inside Canada anyways, so if need arises I can sponsor them afresh without any questions on departure order in the PR sponsorship application

If they accept PRTD means our status is safe and we are assured of PR cards. Is this correct assumption?

I would appreciate your inputs.

Your situation is very rare so it is tough to predict how IRCC will treat your case. Agree that departure order is unlikely. If already living abroad IRCC would expect that your spouse would want to return home.