It is impossible for stations to replace online railcards as the layout/format is completely different.
Station railcards are on cardboard and the online ones are plastic.
How much are printers that can print plastic cards these days? I see them loads at events/exhibitions, and they're very quick too.
With the inevitable introduction of smartcards, is it time for the industry to consider the introduction of these at stations, so people will get railcards and season tickets on plastic - and can have unique information printed on, such as a photograph? You could even have a camera at one of the windows to take a photo of the person there and then, storing that image on file so future tickets can be printed out and posted, with the industry knowing that the photo is genuine.
Yes, there would be a large cost - but there's going to be a large cost for the next generation of ticketing, and I'd hate to see the opportunity missed.