Hi all,
I recently applied PIO for my new born and had lots and lots of queries. 
So i thought i will make a thread where i will share my experience so that others will find it useful.

Before beginning for PIO card (Indian visa) 
u need to have ur baby's Birth certificate (provided in all the hospitals)
And Baby's US Passports ( when taking photos for passport make 4 copies extra )-it can be used for visa. try taking photos by urself if possible it will reduce cost but involves lot of efforts.

epassportphoto is the site where i took and uploaded my sons photo and printed in the photolab which has 5 photos(.75 cents)

We are in Florida so i need to send out my sons visa to Houston so check on where to send urz in the site.

Now the visa process in outsourced to TRAVISA 
Steps:
1. Go to the TRAVISA website ->Indian PIO Center
2. Get the Requirements by filling few info about urself(like US citizen,New PIO Minor etc...)

-Fill the order form (this had Application id ( can be filled online only)

3. Need to fill in the PIO application form ( u need to fill and take a print out then and there) Type in all the info and print 3 copies( need to send 2 to consulate one for ur copy)
i)Paste 2 photos in each PIO form and clip 2 photos.
II)Baby's Birth certificate(copy)
iii)US passport original
iv)Copy of Passport pages last 25,26,27 and the information page.
V) Marriage certificate if ur name is diff from the one in Passport( i dint keep one)
vi)Parents visa ,I94 and EAD 
vii) Address Proof - Driving License preferable.
viii)Money order $188 and $12 also make a copy and keep it for ur reference
( i took it in AMSCOT and it was free)

TIPS:
Some say the copies u sent need to be notarized and i dint do anything.

also u need to keep the Thumb impression of the baby in PIO form (left thumb for boys and right for gals)

Please get a stamp pad and keep the thumb impression when baby is sleeping.

Once all done u nee to send them a return shipping label.
My head rolled on this .....but found some easy way.
enquired in Fedex,USPS etc.. and atlast found that UPS has a easy way.

Follow these steps..( i choosed UPS 3 day option for return ) - charged $10 totally. choosed Electronic shipping label (label will be mailed to ur email)
Planning to send thr USPS registred post 

HINt: put ur baby;s PIO application id in the "Merchandise info" so that i will be easy to track and package cannot be missed by PIO office

Please create UPS account number and then in the Shipping-> Create return.

Just listed few steps:

1. Create a UPS Account (if you don't have one).
2. Under 'My UPS Profile' you can setup payment to one of your Credit cards.
3. Choose options - Shipping > Create Return > .. fill up all information .
(Section 4. Label Delivery Method - Select ' PRINT AND MAIL RETURN LABEL'from the various options.)
NOTE : the Company Name for your return Package is Travisa and the Return Address is your Residence to get the pkg back.)
4. At the completion of the record, you have the option to PRINT the Shipping Return label, 
and Mailed with your Documents to Travisa.

As the payment is directly to your UPS account, an no credit card information is on the Shipping label - 
this method is safe/acceptable.

TIP : Good idea to document your Travisa Application Order ID# in the 'Merchandise Information' description column, which is also printed on the Shipping Label.
This would prompt the Travisa staff to ensure they line up the pkg contents correctly.

Hope this is helpful. 


all the best  Will let u know once i receives Sanjay's PIO