How We Delivered 820 Custom Badge Holders to ClearScore in 6 Weeks

How It Started

It started with a single holder. I'd made a custom ID card holder for ClearScore's CEO as a freebie to show what was possible. He liked it enough to pass it along to his Chief of Staff, who got in touch about a much bigger project: their upcoming summer event.

ClearScore were hosting a major company event with around 400 employees and 400 external partners. They wanted every single person to have a fully personalised badge holder with ClearScore branding. Each division had its own colour: turquoise for the Car Mission (DriveScore and car finance), red for Open Banking, and orange for the rest of ClearScore. All with white logo and text.

820 Unique Designs

This wasn't a case of printing 820 identical holders. Every single one was different. I worked with the ClearScore design team and Chief of Staff to put together a detailed spreadsheet of all 820 names and details.

Employee holders had their name and the area of the business they worked in. Partner holders had their name and their respective company. Some were made for notable guests, including Mo Gawdat, who was guest speaking at the event, and Nigel Morris, co-founder of Capital One and a ClearScore board member.

The Production Challenge

This was my biggest order at the time, and my process wasn't built for it yet. I copied each person's name into the 3D model, exported the body and the name/logo as separate files, then aligned and merged them in the slicer by hand. For 820 holders, that's a lot of repetitive work.

Since then, I've built a Python script that ingests a CSV of names, adjusts the font size based on name length so everything fits, modifies the model, and exports a ready-to-print file. I also discovered you can export as a STEP file from Fusion 360, which skips the entire manual alignment step in the slicer. The process is much faster now, but for this job, it was all done the hard way.

6 Weeks, Minus Glastonbury

By the time the team signed off the designs and final numbers, I had 6 weeks to print everything. To make things more interesting, I was also going to Glastonbury for 6 days right in the middle of the production window.

In the last 3 weeks I was printing around the clock. I was getting up multiple times in the night to clear the build plate and start the next print. There were last minute additions right up until the night before the event. It was intense, but every holder was ready in time.

The Event

I'll admit I was running on very little sleep by the time the event came around, but the response made it worth it. Several external partners posted photos of their holders on LinkedIn, which was great to see. And the CEO gave a shoutout to the whole company acknowledging the effort that went into making them, which meant a lot.

Quick Stats

What I Learned

This job changed how I work. The manual process of copying names one by one and aligning files in the slicer taught me that I needed proper tooling. The Python script I built afterwards means I can now handle an order like this in a fraction of the time, and the quality is more consistent because there's less room for human error.

It also proved that fully personalised badge holders at scale are possible with 3D printing. No tooling costs, no minimum batch sizes per design, and one unique holder per person.

Want Something Similar?

If your company is planning an event, onboarding new starters, or wants custom ID card holders for the office, get in touch. The process is much faster now, and I can handle orders from 50 to 5,000+ units. You can preview your own design using our 3D designer tool, or send project details for a free quote.