ⓘ This article is for Event Organizers
Now that you’ve designed your badge shell, it’s time to build the Print Layer. This layer includes the attendee-specific data that will be printed onsite at your event using Expo Pass thermal printers.
💡 Fun Fact: Our thermal printers use heat, similar to a receipt printer, to imprint data onto the white space on the front of the badge.
If you haven’t designed your badge shell yet, be sure to complete that step first.
Designing Your Expo Pass Badge Print Layer: The Basics
The Print Layer contains all the dynamic attendee information that appears on each badge, such as names, titles, organizations, and QR codes. Below, we’ll walk through the fundamentals of navigating the Badge Designer Print Layer in Expo Pass.
🔑 Key Terms to Know
Print Layer:
The editable layer where attendee-specific data is placed, including mail merge fields, QR codes, and static elements such as text or shapes.
Mail Merge:
The attendee information pulled directly from your event, sourced from your Attendee Upload Data or Registration Form. This ensures that each badge prints unique to each attendee.
Safe-to-Print Zone (dotted line):
The boundary where all print-layer elements must remain inside to ensure proper alignment and print accuracy.
Getting Started
1. Log in to Expo Pass and choose your event.
2. Click on Onsite ➜ Design Badges. The Badge Manager will pop up. Click on Get Started.
💡 NOTE: If you have already created a badge shell and print layer, the Badge Manager "Get Started" will no longer pop up.
To create a second badge shell, click Create New Badge OR hover the Print Layer you want to change and click Edit.
3. Follow the steps below to create a new badge:
Adding Print Layer Elements
Once you’ve created your Print Layer and badge, it’s time to add elements such as merge fields and QR codes to bring your badge to life.
After creating a new badge, whether through the Get Started flow or by selecting Create New Badge, you’ll land on the screen shown below. You’ll begin in the Shell view (top left).
1.Click Print to switch to the Print Layer and start adding your elements.
![Loom Cropping - 4 December 2025.mp4 [video-to-gif output image]](https://downloads.intercomcdn.com/i/o/ij3yrbte/1865900366/7b485556835df8ee3f29f2a68c12/ezgif-82f8ce0e5e4a95af.gif?expires=1766221200&signature=2cb0605dbe70b3b09cb271140153f534789027254dea5b4ef2dff6a6190829aa&req=dSghE8B%2BnYJZX%2FMW1HO4zeebG%2FcsvvgW%2BK%2BaN74AVjYR072wPfEl7WbcWIJe%0Apx7%2FOarVjsPeCQWUTfQ%3D%0A)
2. Click on the green + button at the bottom of the page to open the selection menu
3. Within the menu, there are 5 options to choose from (see next section for detailed walk through of each of the below options):
Mail Merge (required): This is the attendee data pulled directly from your event from the Attendee Upload Data or Registration Form Data. This will adjust to each unique attendee's information
QR Code: There are 2 options for your QR CODES
Expo Pass: To be used for Expo Pass Session Tracking and/or Lead Retrieval
Custom: To be used when needed a custom QR code from an external source or application that is unique to each attendee
*Please reach out to Event Success if you are planning on using a Custom QR code, as this requires further discussion and planning.
Text: This is when you would like to add text to the print layer that is the same for all badges.
Example - Guest Of:
Image: This is for adding a black only image to the badge print layer that is printed by the thermal printers and the same on all badges.
Shape: This is for adding a black only shape to the badge print layer that is printed by the thermal printers and the same on all badges.
4. Continue by selecting each of the Print Layer elements you would like printed on your badge.
❗ Important:
Keep elements away from the dotted line (aka the Safe-To-Print line)
Anything touching or overlapping this line may not print correctly.
Leave at least 1/8” of space for the best results.
Smart Print Safeguards:
Outside of Safe-to-Print Zone: If any content extends outside the safe print boundary, you’ll receive an alert.
Overlapping Field Boxes: If your field boxes overlap, you will also be flagged to ensure readability and proper formatting.
These notifications will help you design with confidence and avoid last-minute printing issues.
5. Once you have added all the desired data to the print layer click Done.
What's Next?
Congratulations!! Now you've gotten comfortable with designing your Badge Print Layer. Let's get a little more into the details.