diff --git a/src/lib/ae_events/types/ae_badge_template_cfg.ts b/src/lib/ae_events/types/ae_badge_template_cfg.ts
index 83a43f46..52d986fa 100644
--- a/src/lib/ae_events/types/ae_badge_template_cfg.ts
+++ b/src/lib/ae_events/types/ae_badge_template_cfg.ts
@@ -76,6 +76,10 @@ export interface BadgeTemplateCfg {
         center_bg?: string;
         center_rainbow?: boolean;
         slow_pulse?: boolean;    // when true: slow breathing pulse instead of fast linear cycle
+        // Extra horizontal inset per side (mm) beyond the 1mm base safety margin.
+        // Shrinks the visible marker width to keep it inside the physical hole on
+        // printers or badge stock with variance. Default 2 when unset (see view component).
+        inset_x_mm?: number;
     };
 
     // Allow arbitrary extra keys to preserve forward-compatibility.
diff --git a/src/routes/events/[event_id]/(badges)/badges/[badge_id]/ae_comp__badge_obj_view.svelte b/src/routes/events/[event_id]/(badges)/badges/[badge_id]/ae_comp__badge_obj_view.svelte
index 792d73de..28f1ff49 100644
--- a/src/routes/events/[event_id]/(badges)/badges/[badge_id]/ae_comp__badge_obj_view.svelte
+++ b/src/routes/events/[event_id]/(badges)/badges/[badge_id]/ae_comp__badge_obj_view.svelte
@@ -332,6 +332,11 @@ let punch_holes_left   = $derived(!!template_cfg?.punch_holes?.left);
 let punch_holes_right  = $derived(!!template_cfg?.punch_holes?.right);
 let punch_holes_center = $derived(!!template_cfg?.punch_holes?.center);
 
+// Horizontal inset per side applied to each marker, in mm.
+// Default 2mm — enough to stay inside the hole on real badge stock with typical printer variance.
+// Increase via punch_holes.inset_x_mm in the template config if a printer or stock runs long.
+let punch_holes_inset_x = $derived(template_cfg?.punch_holes?.inset_x_mm ?? 2);
+
 // Per-slot colors: slot-specific override → shared fallback → component default.
 // When rainbow is on and no explicit fg/bg is set, use a saturated base color so
 // hue-rotate produces a full visible spectrum (gray has no hue to rotate).
@@ -697,7 +702,10 @@ const code_to_icon: {
             <!-- Punch-out hole markers: X overlays at physical badge clip slot positions.
                  Slots: 5/8in wide × 1/8in tall, 1/4in from top, 3/8in from left/right edges.
                  z-index: 10 keeps markers above the header image regardless of DOM order.
-                 Inset ~1mm on all sides — safety margin for printer registration variance.
+                 Horizontal inset = punch_holes_inset_x mm per side (default 2mm) — keeps the
+                 marker inside the physical hole across printers and badge stock with variance.
+                 Vertical inset is fixed at 1mm (top and bottom). Configurable per template via
+                 punch_holes.inset_x_mm in the template cfg_json.
 
                  Rainbow sync: rainbow markers share ONE wrapper div with the hue-rotate animation.
                  A single CSS animation on the wrapper drives all children simultaneously — no
@@ -712,7 +720,7 @@ const code_to_icon: {
                      class:punch_hole_rainbow_left={!punch_holes_slow_pulse}
                      class:punch_hole_pulse_left={punch_holes_slow_pulse}
                      aria-hidden="true"
-                     style="top: calc(0.25in + 1mm); left: calc(0.375in + 1mm); width: calc(0.625in - 2mm); height: calc(0.125in - 2mm); z-index: 10;">
+                     style="top: calc(0.25in + 1mm); left: calc(0.375in + {punch_holes_inset_x}mm); width: calc(0.625in - {punch_holes_inset_x * 2}mm); height: calc(0.125in - 2mm); z-index: 10;">
                     <svg width="100%" height="100%" viewBox="0 0 50 8" preserveAspectRatio="none" xmlns="http://www.w3.org/2000/svg">
                         <rect x="0.5" y="0.5" width="49" height="7" fill={punch_holes_colors.left.bg} stroke={punch_holes_colors.left.fg} stroke-width="1" stroke-dasharray="4,2"/>
                         <line x1="0" y1="0" x2="50" y2="8" stroke={punch_holes_colors.left.fg} stroke-width="1"/>
@@ -721,7 +729,7 @@ const code_to_icon: {
                 </div>
                 <div class="punch_hole_marker punch_hole_print_rgb pointer-events-none absolute"
                      aria-hidden="true"
-                     style="top: calc(0.25in + 1mm); left: calc(0.375in + 1mm); width: calc(0.625in - 2mm); height: calc(0.125in - 2mm); z-index: 10;">
+                     style="top: calc(0.25in + 1mm); left: calc(0.375in + {punch_holes_inset_x}mm); width: calc(0.625in - {punch_holes_inset_x * 2}mm); height: calc(0.125in - 2mm); z-index: 10;">
                     <svg width="100%" height="100%" viewBox="0 0 50 8" preserveAspectRatio="none" xmlns="http://www.w3.org/2000/svg">
                         <defs><linearGradient id="ph_rg_left" x1="0%" y1="0%" x2="100%" y2="0%"><stop offset="0%" stop-color="#ff0000"/><stop offset="20%" stop-color="#ffff00"/><stop offset="40%" stop-color="#00ff00"/><stop offset="60%" stop-color="#00ffff"/><stop offset="80%" stop-color="#0000ff"/><stop offset="100%" stop-color="#ff00ff"/></linearGradient></defs>
                         <rect x="0.5" y="0.5" width="49" height="7" fill="url(#ph_rg_left)" stroke="url(#ph_rg_left)" stroke-width="1" stroke-dasharray="4,2"/>
@@ -735,7 +743,7 @@ const code_to_icon: {
                      class:punch_hole_rainbow_right={!punch_holes_slow_pulse}
                      class:punch_hole_pulse_right={punch_holes_slow_pulse}
                      aria-hidden="true"
-                     style="top: calc(0.25in + 1mm); right: calc(0.375in + 1mm); width: calc(0.625in - 2mm); height: calc(0.125in - 2mm); z-index: 10;">
+                     style="top: calc(0.25in + 1mm); right: calc(0.375in + {punch_holes_inset_x}mm); width: calc(0.625in - {punch_holes_inset_x * 2}mm); height: calc(0.125in - 2mm); z-index: 10;">
                     <svg width="100%" height="100%" viewBox="0 0 50 8" preserveAspectRatio="none" xmlns="http://www.w3.org/2000/svg">
                         <rect x="0.5" y="0.5" width="49" height="7" fill={punch_holes_colors.right.bg} stroke={punch_holes_colors.right.fg} stroke-width="1" stroke-dasharray="4,2"/>
                         <line x1="0" y1="0" x2="50" y2="8" stroke={punch_holes_colors.right.fg} stroke-width="1"/>
@@ -744,7 +752,7 @@ const code_to_icon: {
                 </div>
                 <div class="punch_hole_marker punch_hole_print_rgb pointer-events-none absolute"
                      aria-hidden="true"
-                     style="top: calc(0.25in + 1mm); right: calc(0.375in + 1mm); width: calc(0.625in - 2mm); height: calc(0.125in - 2mm); z-index: 10;">
+                     style="top: calc(0.25in + 1mm); right: calc(0.375in + {punch_holes_inset_x}mm); width: calc(0.625in - {punch_holes_inset_x * 2}mm); height: calc(0.125in - 2mm); z-index: 10;">
                     <svg width="100%" height="100%" viewBox="0 0 50 8" preserveAspectRatio="none" xmlns="http://www.w3.org/2000/svg">
                         <defs><linearGradient id="ph_rg_right" x1="0%" y1="0%" x2="100%" y2="0%"><stop offset="0%" stop-color="#ff0000"/><stop offset="20%" stop-color="#ffff00"/><stop offset="40%" stop-color="#00ff00"/><stop offset="60%" stop-color="#00ffff"/><stop offset="80%" stop-color="#0000ff"/><stop offset="100%" stop-color="#ff00ff"/></linearGradient></defs>
                         <rect x="0.5" y="0.5" width="49" height="7" fill="url(#ph_rg_right)" stroke="url(#ph_rg_right)" stroke-width="1" stroke-dasharray="4,2"/>
@@ -758,7 +766,7 @@ const code_to_icon: {
                      class:punch_hole_rainbow_center={!punch_holes_slow_pulse}
                      class:punch_hole_pulse_center={punch_holes_slow_pulse}
                      aria-hidden="true"
-                     style="top: calc(0.25in + 1mm); left: 50%; transform: translateX(-50%); width: calc(0.625in - 2mm); height: calc(0.125in - 2mm); z-index: 10;">
+                     style="top: calc(0.25in + 1mm); left: 50%; transform: translateX(-50%); width: calc(0.625in - {punch_holes_inset_x * 2}mm); height: calc(0.125in - 2mm); z-index: 10;">
                     <svg width="100%" height="100%" viewBox="0 0 50 8" preserveAspectRatio="none" xmlns="http://www.w3.org/2000/svg">
                         <rect x="0.5" y="0.5" width="49" height="7" fill={punch_holes_colors.center.bg} stroke={punch_holes_colors.center.fg} stroke-width="1" stroke-dasharray="4,2"/>
                         <line x1="0" y1="0" x2="50" y2="8" stroke={punch_holes_colors.center.fg} stroke-width="1"/>
@@ -767,7 +775,7 @@ const code_to_icon: {
                 </div>
                 <div class="punch_hole_marker punch_hole_print_rgb pointer-events-none absolute"
                      aria-hidden="true"
-                     style="top: calc(0.25in + 1mm); left: 50%; transform: translateX(-50%); width: calc(0.625in - 2mm); height: calc(0.125in - 2mm); z-index: 10;">
+                     style="top: calc(0.25in + 1mm); left: 50%; transform: translateX(-50%); width: calc(0.625in - {punch_holes_inset_x * 2}mm); height: calc(0.125in - 2mm); z-index: 10;">
                     <svg width="100%" height="100%" viewBox="0 0 50 8" preserveAspectRatio="none" xmlns="http://www.w3.org/2000/svg">
                         <defs><linearGradient id="ph_rg_center" x1="0%" y1="0%" x2="100%" y2="0%"><stop offset="0%" stop-color="#ff0000"/><stop offset="20%" stop-color="#ffff00"/><stop offset="40%" stop-color="#00ff00"/><stop offset="60%" stop-color="#00ffff"/><stop offset="80%" stop-color="#0000ff"/><stop offset="100%" stop-color="#ff00ff"/></linearGradient></defs>
                         <rect x="0.5" y="0.5" width="49" height="7" fill="url(#ph_rg_center)" stroke="url(#ph_rg_center)" stroke-width="1" stroke-dasharray="4,2"/>
@@ -781,7 +789,7 @@ const code_to_icon: {
             {#if punch_holes_left && !punch_holes_left_rainbow}
                 <div class="punch_hole_marker pointer-events-none absolute"
                      aria-hidden="true"
-                     style="top: calc(0.25in + 1mm); left: calc(0.375in + 1mm); width: calc(0.625in - 2mm); height: calc(0.125in - 2mm); z-index: 10;">
+                     style="top: calc(0.25in + 1mm); left: calc(0.375in + {punch_holes_inset_x}mm); width: calc(0.625in - {punch_holes_inset_x * 2}mm); height: calc(0.125in - 2mm); z-index: 10;">
                     <svg width="100%" height="100%" viewBox="0 0 50 8" preserveAspectRatio="none" xmlns="http://www.w3.org/2000/svg">
                         <rect x="0.5" y="0.5" width="49" height="7" fill={punch_holes_colors.left.bg} stroke={punch_holes_colors.left.fg} stroke-width="1" stroke-dasharray="4,2"/>
                         <line x1="0" y1="0" x2="50" y2="8" stroke={punch_holes_colors.left.fg} stroke-width="1"/>
@@ -792,7 +800,7 @@ const code_to_icon: {
             {#if punch_holes_right && !punch_holes_right_rainbow}
                 <div class="punch_hole_marker pointer-events-none absolute"
                      aria-hidden="true"
-                     style="top: calc(0.25in + 1mm); right: calc(0.375in + 1mm); width: calc(0.625in - 2mm); height: calc(0.125in - 2mm); z-index: 10;">
+                     style="top: calc(0.25in + 1mm); right: calc(0.375in + {punch_holes_inset_x}mm); width: calc(0.625in - {punch_holes_inset_x * 2}mm); height: calc(0.125in - 2mm); z-index: 10;">
                     <svg width="100%" height="100%" viewBox="0 0 50 8" preserveAspectRatio="none" xmlns="http://www.w3.org/2000/svg">
                         <rect x="0.5" y="0.5" width="49" height="7" fill={punch_holes_colors.right.bg} stroke={punch_holes_colors.right.fg} stroke-width="1" stroke-dasharray="4,2"/>
                         <line x1="0" y1="0" x2="50" y2="8" stroke={punch_holes_colors.right.fg} stroke-width="1"/>
@@ -803,7 +811,7 @@ const code_to_icon: {
             {#if punch_holes_center && !punch_holes_center_rainbow}
                 <div class="punch_hole_marker pointer-events-none absolute"
                      aria-hidden="true"
-                     style="top: calc(0.25in + 1mm); left: 50%; transform: translateX(-50%); width: calc(0.625in - 2mm); height: calc(0.125in - 2mm); z-index: 10;">
+                     style="top: calc(0.25in + 1mm); left: 50%; transform: translateX(-50%); width: calc(0.625in - {punch_holes_inset_x * 2}mm); height: calc(0.125in - 2mm); z-index: 10;">
                     <svg width="100%" height="100%" viewBox="0 0 50 8" preserveAspectRatio="none" xmlns="http://www.w3.org/2000/svg">
                         <rect x="0.5" y="0.5" width="49" height="7" fill={punch_holes_colors.center.bg} stroke={punch_holes_colors.center.fg} stroke-width="1" stroke-dasharray="4,2"/>
                         <line x1="0" y1="0" x2="50" y2="8" stroke={punch_holes_colors.center.fg} stroke-width="1"/>