The new $100 bill includes advanced anti-counterfeit measures like a 3D security strip that could cause production delays.
Recently during printing of the new bills, the paper folded on the press, creating unprinted creases. At least $110 billion worth of the new hundreds are unusable.
Officials say the new bill is the most expensive ever produced, costing 12 cents a piece.
The recent printing error equates to about $120 million in bills that cannot be used.
The new $100 bills are expected to release in February 2011.