All great suggestions, but they are doctors, so they get their way. Infrequent downloading because they're too busy most of the time. We also had originally set up a 'never to leave the office with this device' policy, but now we're replacing about 1 a month due to lost items(lost at home, in another state, on a plane, in the lake). That's why I'm more in the mood of finding some decent recovery software than changing how they handle them. It's just impossible. Anyway, I found Runtime Software's "GetDataBack for FAT" that runs on Windows. It's recovered them and seems to be working fine.
I would suggest reformatting the cards more frequently. I have had similar problems with card corruption in a digital camera and frequent reformatting seems to have fixed that problem. Considering the medical nature of the data being stored, pull each card aside once a week and format it to be safe. You might also consider tracking corruption for each card so you can tell if it's one or two cards that are the problem, or the whole batch.
I'd suggest increasing the frequency of cradle visits. When the
machines corrupt the drives, is the most-recently-recorded data also
corrupt, or just the other data that hasn't seen a cradle yet?
I seem to recall that the FAT filesystems have a backup table, too.
But it's been ages since I fiddled with fsck.vfat
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