I use Xapo and have to say that I'm satisfied. For me it's important to have reliable card and service, also legit and fuly regulated so that I don't have any problems and not only the cheapest. I think that Xapo is doing a good job and I can recommend this card to other users. And with more competition on the market the services should be even better and improved.
You've said that Xapo is fully regulated. Please describe, what kind of regulation is it? As I know, all of such projects aren't regulated, because you're dealing with Bitcoin, so it is interesting for me what kind of regulation are you talking about.
Some info from my personal card experience. Recently I've got free unichange.me virtual card, used it for online payments and it works totally fine for me

I also ordered plastic card for ATM withdrawals and waiting for my card now. Hope that using plastic card will be smooth as well)
Among other things I like about these guys is that I do not need to store money there, like for example you need to fund Xapo wallet to withdraw funds to your Xapo card. With Unichange I receive payment directly to card, which means that funds are stored on the card issued by EMI licensed card provider