As I am understanding your answer, David, the Print membership card process output is not open to editing by the user (me).
In that case, I'd like to change this from a question to a request of Altru: Please edit the "set list of merge fields" to include email addresses.
Why? Here's just two reasons - Email addresses are incredibly important information to support communications with members (nowadays, virtually as important as the mailing address). Plus, since the Run Acknowledgments process output includes email addresses, apparently someone, at some point, agreed.
As regards the workaround - it is just that, a workaround. As as stopgap, I'll give it a try, though, but first I need to know where to find the option to create an Export definition. I'm not finding any thing in the Edit process box.
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How to edit output of print membership card process topic.