Choose the right badge and printer for your event

Discover how to choose the right badge type and printer for your event. This guide compares options, highlights key features, and offers recommendations for efficient check-ins and smooth badge printing.

 

Thermal Badges Options

1. Direct Thermal Fanfold Paper Badges (Tear - Resistant)
2. PVC Badges with Replaceable Stickers (Direct Thermal)

Tear-Resistant Direct Thermal Fanfold Paper Badges

The Tear-Resistant Direct Thermal Fanfold Paper name badges are designed for seamless, on-demand printing at events such as conferences, tradeshows, meetings, and corporate gatherings. The triple-slot design with intact ‘chad’ allows for flexible lanyard attachments, either single or double-slot, ensuring versatility in how the badges are worn. After printing, the badges are fan folded for easy storage and transport, helping save space.

 

Available Sizes:

• 4x3 Badge: Unfolded dimensions of 4" x 6" with an imprint area of 1-4" x 5-3/4". Ideal for essential attendee information.
• 4x6 Badge: Unfolded dimensions of 4" x 12" with an imprint area of 3-7/8" x 11-5/8". Perfect for events needing more space for logos, agendas, and barcodes.

Key Features:

• Tear-Resistant: Durable 9 pt reinforced material, designed for durability in busy environments.
• Customization: Full-color, double-sided printing with ample space for all relevant event details.
• Slot Design: Triple-slot with intact 'chad' for both single-slot and double-slot lanyard attachments.
• Clean Separation: Perforated edges for easy, neat separation of badges.
• Post-Printing Fold: Fanfolded for compact storage and easy transport.

 

 

Pros

1. Can be used with thermal printers (Thermal printers print faster - 2 seconds per badge) 
2. Cost-effective solution as compared to ZC10L or Epson printers. 
3. Does not require badge holders because it is tear-resistant AND has lanyard slots. 
4. Minimal Consumables: When using direct thermal printing for paper badges, there’s no need for ribbons or ink, unlike thermal transfer printing. This reduces ongoing consumable costs and simplifies the printing process.
5. Lightweight: Paper badges and ZD620/ZD621 printers are lightweight and easy to handle.

Cons:

1. Monochrome Printing: Direct thermal badges and printers are typically limited to black-and-white printing. This restricts the ability to print color logos or other intricate designs, making it less suitable for badges requiring multi-color graphics. The artwork therefore would have to be pre-printed before.
2. Single-use and non-reusable.
3. Can not print in languages other than English 
4. Can only support limited fonts. 

PVC Badges with Replaceable Stickers (Direct Thermal) - Pre-Printed Badge Option

 

PVC badges with customizable 3x3” and 3x2” stickers provide a durable and cost-effective solution for various identification needs. Made from water-resistant, scratch-resistant PVC, these badges are built to withstand daily wear, making them perfect for both indoor and outdoor use.

Key Features:

• Durable PVC Material: Waterproof and scratch-resistant for long-lasting performance.
• Customizable Stickers: Available in 3x3” and 3x2” sizes, ideal for names, logos, barcodes, or QR codes. Stickers are easily replaceable, allowing for quick updates without needing a new badge.
• Printing Technology: Compatible with both direct thermal (no ink or ribbons required) and thermal transfer (for more durable prints) printers.

Ideal for multiday event passes, and visitor badges, these PVC badges offer an efficient, customizable, and durable identification solution.

Pros:

• Durability: PVC badges are waterproof and scratch-resistant, ideal for both indoor and outdoor use.
• Cost-Effective: Replaceable stickers reduce costs, and no ink or ribbons are needed for direct thermal printing on the stickers.
• Customization: Stickers (3x3” and 3x2”) can include logos, names, or QR codes, and are easily replaceable.

Cons:

• Limited Colors: The stickers can only be printed in Black
• The artwork on PVC badges needs to be pre-printed which requires 4 weeks of production time, hence not suitable for events with tight deadlines.
• The badges can not be directly printed onsite, the only option is to stick adhesive stickers after printing the attendee details for onsite printing. 

PVC Badges vs Tear-Resistant Paper Badges: A Comprehensive Comparison

Feature	PVC Badges	Tear-Resistant Paper Badges
Material	Durable, water-resistant, scratch-resistant PVC.	9 pt reinforced paper, tear-resistant, less durable.
Durability	Waterproof, ideal for long-term use.	Suitable for short-term events, but less durable.
Customization	Replaceable stickers (3x3” & 3x2”). Flexible design.	Full-color, double-sided imprinting.
Size Options	Small (3.74” x 5.31”) and Large (4.37” x 6.30”).	4x3 inches and 4x6 inches fixed sizes.
Imprint Technology	Direct Thermal & Thermal Transfer.	Direct Thermal only.
Cost	Higher initial cost, reusable (only stickers replaced).	Lower cost, disposable after each event.
Printer Compatibility	Works with both Direct Thermal & Thermal Transfer printers.	Works with both Direct Thermal & Thermal Transfer printers.
Applications	Long-term use (ID cards, membership, visitor badges).	Short-term events (conferences, tradeshows, meetings).
Post-Printing Features	Stickers are replaceable.	Fanfolded for easy storage and separation.
Eco-Friendliness	Reusable, less waste.	Single-use, higher waste generation.
Best Suited For	Long-term, reusable badges.	High-volume, one-time use at events.

 

Complete On-Site Colour Printing Option for PVC Badges

 

The Zebra ZC10L Printer is a versatile solution for onsite full-color badge printing at events with large attendance, offering quick, high-quality results with full control over the process. Ideal for printing professional-looking badges in seconds, it’s perfect for events with 1,000+ attendees, ensuring efficient and hassle-free badge production.

Sample Badge:

 

 

Key Features:

• Prints 3-1/2" x 5-1/2" plastic cards (sold separately), 24 mil thick.
• 300 dpi resolution for vibrant, photo-quality images and crisp text.
• Prints up to 6 badges per minute, ideal for large events.

Pros:

• Fast Onsite Printing: Prints full-color, photo-quality badges in seconds, ideal for events with shorter turnaround times as you can skip pre-printing design elements on the badges.
• High-Quality Output: 300 dpi resolution delivers sharp images, vibrant colors, and crisp text.
• Efficient: Prints up to 6 badges per minute, reducing wait times for attendees.

Cons:

• Limited Size of Cards: Designed for larger cards (3-1/2" x 5-1/2" - 3.5"X5.5" plastic cards), which may not be suitable for events requiring standard-sized ID cards.
• Single Sided Printing: The printing of design elements is only possible on the front of the badges whereas the back of the badge will remain plain/blank.
• Slower than Compact Printers: May not be ideal for high-volume, rapid badge printing in very large events.
• Bulkiness: The ZC10L is larger and may require more space compared to compact badge printers.
• Not a Cost Effective Option: The cost of 24 mil plastic cards and consumables may add up, especially for large events. ZC10L costs more than ZD620/621 printers. 

Summary:

The Zebra ZC10L Printer is an excellent choice for onsite, full-color badge printing at events, delivering quick, professional-looking badges with high-quality results. While it’s optimized for large-format badges and high-quality printing, its speed and cost considerations may not suit events requiring rapid, high-volume smaller badge production.

 

Complete On-Site Colour Printing Option for Paper Card Tear-Resistant Badges

Epson printers, such as the ColorWorks C4000 are designed for high-quality, on-demand printing, ideal for name tags, badges, and other event materials. These printers deliver full-color, photo-quality prints with high resolution (up to 1200 dpi) and precise QR code printing. They are compatible with Epson's Inkjet Poly Fanfold Paper, ensuring durability with tear, smudge, and water resistance.

 

Sample Badge:

 

Pros:

• Fast print speeds (up to 4 inches per second)
• Self-adjusting and self-cleaning print heads
• Efficient ink usage with individual ink cartridges

Cons:

• Expensive as compared to monochrome printers
• Although the C4000 produces good color prints, it might not be ideal for professional graphic design or photography work where precise color matching is essential. The color gamut may not be as wide as some higher-end models.

 

Badge Options Compatible with Epson Printers:

Badge Type	Dimensions (inches)	Perforation	Lanyard Slots	Key Features
Double-Sided 4" x 3" Tear-Resistant	4" x 6" (perforated at every 3")	Perforation at every 3"	3 perforated slots	Compact size, perfect for small name tags, tear-resistant, matte finish.
Double-Sided 4" x 5" Tear-Resistant	4" x 10" (perforated at every 5")	Perforation at every 5"	3 perforated slots	Larger size, ideal for more text or logos, tear-resistant, and water-resistant.
Butterfly 3.8" x 3.2" Tear-Resistant	3.8" x 3.2"	No perforation (single badge size)	3 perforated slots	Unique butterfly shape, compact and stylish, tear and water-resistant.
Butterfly 3.8" x 5.3" Tear-Resistant	3.8" x 5.3"	No perforation (single badge size)	3 perforated slots	Larger butterfly shape, tear and water-resistant, great for more content.

 

Overall Badge Comparison Table

Feature	PVC Badges with Direct Thermal Stickers	Tear-Resistant Paper Badges	On-Site Full-Color Printing (Epson ColorWorks C4000)	On-Site Full-Color Printing (Zebra ZC10L)
Material	Water-resistant, scratch-resistant PVC with Direct Thermal Stickers (Clear or White stickers)	Tear-resistant 9 pt paper	Tear-resistant paper (matte finish, Epson Inkjet Poly)	Plastic, designed for large-format badges (3.5" x 5.5")
Durability	Highly durable, ideal for long-term use with replaceable stickers	Less durable, ideal for short-term use (events)	Tear and water-resistant, designed for event use	High Durability
Water Resistance	Yes	No	No	Yes
Scratch Resistance	No	Yes	Yes	No
Customization	Replaceable thermal stickers (3x3” & 3x2”), logos, names, QR codes	Full-color, double-sided printing with space for event info	Full-color, photo-quality prints, logos, QR codes	Full-color, photo-quality prints, logos, QR codes
Imprint Technology	Direct Thermal only	Direct Thermal only	Inkjet (Epson ColorWorks C4000)	Dye-sublimation (Zebra ZC10L)
Color Printing	Monochrome (Black)	Monochrome (Black)	Full-color (high resolution up to 1200 dpi)	Full-color (300 dpi resolution)
Onsite Printing	No (requires pre-printed badges with only sticker printed in black onsite)	No (requires pre-printed badges and only attendee details are printed in black on site)	Yes, full-color printing directly on badges	Yes, full-color printing on large-format badges
Initial Cost	Higher due to PVC material and Direct Thermal stickers	Lower cost, disposable after each event	Higher due to printer and ink cost	Higher due to printer and consumables cost
Badge Holder Required	No	No	No	No
Size Options	Small (3.74” x 5.31”) and Large (4.37” x 6.30”) - Sticker size 3x2 inches and 3x3 inches	4x3 inches and 4x6 inches fixed sizes. (Double Sided Badges)	4" x 5", 4" x 3" and 4" x 6" Butterfly 3.8"x 5.3" Tear Resistant Badges w/ 3 CLIP HOLES Butterfly 3.8"x 3.2" Tear Resistant Badges w/ 3 CLIP HOLES	3.5"X5.5" plastic cards
Cost-Effectiveness	Cost-effective over long-term (reusable with new stickers)	Low cost for one-time use (disposable)	Not cost-effective for large events, higher consumables	Not cost-effective for large events, higher consumables
Consumables	Direct thermal stickers, no ink or ribbon needed	No consumables other than the badges (no ribbons/inks)	Ink cartridges and badges required	Badge cards and ribbons required
Printing Speed	Fast (thermal printers print at 2 seconds per badge)	Fast (thermal printers print at 2 seconds per badge)	Moderate (up to 4 inches per second)	Moderate(up to 6 badges per minute)
Printer Compatibility	Direct Thermal only	Direct Thermal only	Epson ColorWorks (Inkjet)	Zebra ZC10L (Dye-sublimation)
Best Suited For	Long-term (ID cards, membership, visitor badges)	Short-term, high-volume events (conferences, tradeshows)	Events requiring professional, full-color badges	Large events with rapid, high-quality badge production
Post-Printing Features	Replaceable stickers	Fanfolded for compact storage	On-site printing with full-color design	On-site printing, professional-quality badges
Recommended Printers	Zebra ZD620/ZD621, other direct thermal printers	Zebra ZD620/ZD621, other thermal printers	Epson ColorWorks C4000	Zebra ZC10L
Printing Resolution	203 or 300 dpi (direct thermal printers)	203 or 300 dpi (thermal printers)	1200 dpi (Epson ColorWorks)	300 dpi (Zebra ZC10L)
Printer Speed	Moderate (up to 6 badges per minute)	Fast (2 seconds per badge)	Moderate (up to 4 inches per second)	Fast (up to 6 badges per minute)