An acrylic badge is a credential, a souvenir and a scanning target at once, and it is handled more in three days than most products are in a year.
A technology conference printed 2 400 badges on 2 mm stock. Badges cracked at the lanyard slot by day two, and the registration desk ended up issuing replacement cards to a third of attendees.
Acrylic badge thickness and slot design
- Standard credential: 3 mm
- Premium or QR badge: 5 mm
- Slot: 12 by 4 mm rounded, 8 mm edge distance
- Corner: 3 mm radius, no sharp point
Edge distance at the slot is the same rule as any hanging part: material between slot and edge carries the badge weight plus the pull of a lanyard being yanked. Eight mm on 3 mm stock is the practical minimum.
Variable print and the scan panel
Variable data changes the process. UV digital prints a name per badge in one pass; screen print needs a fixed artwork and a separate label for the variable field, which adds a step and a peeling risk.
Scanning needs a matte window or a printed code on an opaque panel. A clear badge over a dark lanyard makes a QR code unreadable at the door, which is the failure that shows up as a queue.
For cut stock at this scale, acrylic cut to size covers tolerance and edge quality.
Send your badge layout, attendee count and scan requirement to oversales@rpplexiglass.com for a badge quote.
Frequently Asked Questions
What thickness acrylic badge?
3 mm for a standard credential, 5 mm for a premium tier badge or one carrying a QR panel. Thinner stock flexes in a lanyard and the print layer cracks at the slot.
How should the lanyard slot be made?
A 12 by 4 mm rounded slot set 8 mm from the top edge. A round hole with a clip works, but a slot lets the badge hang flat instead of rotating on a single point.
Which print method suits variable badges?
UV digital for runs under 500 with variable names, screen print for larger runs with fixed artwork and a printed label for the variable field. Reverse print on clear stock protects the image from wear.