We recently had an update from the Hack.RVA team on the badges for this year’s conference and we had to share!  They have been heavily focused on the etching process the past few months and are making great progress. They tested a spray-on resist with very unpredictable results, and have replaced it with a resist film application, with one more method to test out before making a final decision. Last year the etching stage was a huge time sink and a source of some errors, so they are determined to get it right this year!
The software is currently only in the driver “bring-up” phase, and the only component that hasn’t been tested is the IR, which is the same model used in last year’s badge, only smaller. 
Here is a picture of one of the first prototypes.