ⓘ This article is for Event Organizers
We are excited to get started on designing your unique badge shell for your event
Let's review the basics, and then we can get to the fun part - design time!
At this point you've selected what size badge you want. Below you will find all of Expo Pass's suggestions when designing your badge to ensure you get the best print possible!
🔑 Key Terms to Know
Shell Layer: The fixed background design used on all badges (e.g., logos, colors, borders). It does not change from attendee to attendee.
Print Layer: The layer that overlays attendee-specific information like names, titles, and QR codes. This content is added through the Expo Pass platform, not your uploaded design.
Full Bleed: A printing term that refers to background designs extending all the way past the edge of the badge to the blue line without white borders. This ensures a polished, professional look.
Formed Badges: the combined badge shell and print layers in Expo Pass Badge Manager, used to create and assign the badge(s) for your event.
Bonus Terms:
Crop Marks: the marks added to the badge design that show the printer where to cut.
These are added when the badge is downloaded for print from the Badge Manager in Expo Pass.
CMYK colors: used in print designs.
It is essential to ensure your designs are in the CMYK color scale to ensure accurate color reproduction when badges are printed.
RGB colors: used in digital display designs
If you are using RGB for designing, it is essential to convert to CMYK before submitting for print to ensure accurate color production
The Basics
Our badges are priced in full-color shells, and are made of high-quality paper.
Expo Pass uses 9.5 pt. stock, which is much heavier/thicker and holds up very well even without a holder.
Expo Pass badges are printed on direct-thermal paper without the need for messy inks! The reaction of heat being applied to the paper allows for black text and other black images such as a QR code to be visible on the paper.
❗ Important: Attendee data can only be printed via the thermal printer on the FRONT of the badge. The color design can be on the front and back of the badge.
In an effort to manage your expectations, your badge shell design artwork is due to your Expo Pass Success Specialist at least 24 DAYS PRIOR to your event start date.
This is to ensure we have enough time to approve, order, and test your badges, so they are top notch!
If for some reason that timeframe becomes compressed, we cannot guarantee that your badges will be available for your event and/or we will be forced to assess an additional expedited fee.
Badge Design Best Practices for High Quality Print
When designing your badge shell, you can have design on the front and/ or back (usually in color). We have the ability to support either a 4x6" or 4x3" single or double-sided badge shell design.
Use high resolution images (300 DPI minimum)
To ensure your badge design will print crisp. If you upload low resolution images or designs, the print may come out blurry or pixelated.
If you encounter blurry designs, confirm you're using the correct and final version of your design file, and recheck the file quality before submission. Blurry designs often result from using incorrect or low-resolution files.
Use CMYK colors on your images
If you use RGB, the color of the design in the badge designer may differ from the actual print as Expo Pass uses CMYK to print the badge shells in-house
Use Light Colors or White Space for Attendee Data Area
Make sure you account for enough space for all the attendee data without looking crowded and is legible.
We use thermal printers that print in black ink only (like a receipt).
Use Light Backgrounds: To ensure optimal legibility, attendee information should be printed on a white or very light-colored area. Dark or heavily saturated colors can make the text difficult to read.
Minimize Visual Noise: Avoid placing patterns, gradients, logos, or other design elements in the data printing area, as these can interfere with text clarity.
Ensure Sufficient Contrast: Black thermal printing stands out best against light backgrounds, so be mindful of contrast when selecting your badge colors.
By following these guidelines, you can ensure a professional, clean, and highly readable badge design that enhances the attendee experience.
Bleed Area (Blue Box around the badge)
Make sure your background extends 0.125” to fill the bleed and avoid white on edges when trimmed.
We recommend a common top to bottom bleed color to avoid possible color misalignment along perforation.
Stretched or pixelated artwork typically occurs when design dimensions don't account for proper bleed area
Extend badge design approximately a quarter-inch on all sides (resulting in dimensions of 4.25" x 6.25" for 4x6" badges)
Save final files without crop marks, as these are automatically added during the final download
Trim(the edge of the badge)
Where your badges will be cut.
Safe Zone (the dotted grey line)
Make sure to keep important aspects of your design such as logos and text within the safe area.
Before finalizing, always review a complete preview of your badge design
Verify that all necessary bleed areas are accounted for and content is centered appropriately
Check alignment of all key elements relative to the safe zone
4x6" Badges
Bleed Area 4.25” x 6.25” (Blue Box around the badge)
Trim 4” x 6” (the edge of the badge)
Safe Zone 3.75” x 5.34” (the dotted grey line)
4x3" Badges
Bleed Area 4.25" x 3.25" (Blue Box around the badge)
Trim 4" x 3" (the edge of the badge)
Safe Zone 3.75” x 2.34” (the dotted grey line)
❗Safe-to-Print Area Around the Notch
Most Expo Pass badges are printed with a notch or hole at the top for a lanyard. Designing around this area is critical to avoid printing issues.
Leave at least 0.25” (1/4") of clear space around the notch — no text, logos, images, or shapes.
Solid background colors are okay, but avoid detailed graphics or any critical design elements near this area.
Overlapping this zone may trigger printer sensor errors, which can result in:
Misaligned badges
Double prints
Badge jams or reprints
⚠️ Why This Matters: The notch area is where the printer senses each badge. If your design interferes with this space, it may cause your printer to malfunction.
4 x 6" Badge Print Layer Sample
❗ Important: Attendee data can only be printed on the front side of the badge in white space. Expo Pass uses thermal printers and cannot print on color.
4" x 3" Badge Print Layer Sample
❗ Important: Attendee data can only be printed on the front side of the badge in white space. Expo Pass uses thermal printers and cannot print on color.
Black & White Badge Designs
If you are tight on time or want a black and white design, you are able to do so by designing your shell on the Print Layer of your badge. This process works great for printing words and basic images, but is not meant to create black background.
👉 For these badges, it's imperative to remember that the Direct Thermal Printers use heat to alter the badge, creating a black micro-dot.
❗ Important: Black and white can only be printed on the front side of the badge in white space via the thermal printers.
The will be printed onsite at the live event on blank badges along with the attendee data
Sample Black and White Logos | What works and what doesn't
Again, we can't stress enough how important it is to start this design phase as soon as possible.
Common Badge Artwork Issues and Troubleshooting
When preparing your badge artwork, you may encounter common issues that can affect print quality. Here's how to address them: If You Need to Correct Errors in Submitted Artwork:
Immediately send an updated version with explicit details about the corrections needed
Ensure the revised file matches your original intent to minimize additional errors
Note that corrections may impact your production timeline
Next step: Let's get designing!!