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Hi Grahame,
I discovered that the new badge templates in CiviCRM 4.5 can be added through Administer > System Settings > Option Groups > Name Badge Format (/civicrm/admin/options?gid=122&reset=1). Unfortunately, that interface only allows to enter the new badge name and a description but no info about the layout. To actually tell CiviCRM some details about that badge layout, direct database update is required to add that value.

Here is what I did:
1. To know which value to update in the database, run first this query:
SELECT id FROM `civicrm_option_value` WHERE name = "Avery 5392"
where "Avery 5392" is the name of the new badge layout I just added. The result I got was id = 847

2. Enter the layout details for that badge into the DB using this query:
UPDATE civicrm_option_value
SET value = '{"name":"Avery 5392","paper-size":"letter","metric":"mm","lMargin":2,"tMargin":25.4,"NX":2,"NY":3,"SpaceX":0,"SpaceY":0,"width":101.6,"height":76.2,"font-size":12,"orientation":"portrait","font-name":"helvetica","font-style":"","lPadding":3,"tPadding":3}'
WHERE `civicrm_option_value`.`id` = 847;

Update the id = 847 with the id number from the first query.

3. Now, that new layout/template is available when adding new Event Badge Layouts (civicrm/admin/badgelayout?reset=1&action=browse)

Hi Grahame,
Yes, a bit of trial and error because I didn't find any decent documentation for 4.5 related to event badges. As to the values for that particular Avery 5392 template, I copied them from the old custom code I had access to (from the previous CiviCRM version) which we used in custom php file for custom badges (extending CRM_Event_Badge ). That is no longer an option in CiviCRM 4.5 due to the changes in code and how the badges are generated.
I haven't tested those values for Avery 5392 yet, I only got to the point of creating the new format to test during printing. Most likely some dimensions may need to be adjusted, I only used that as an example of adding new template.

It also helped to compare the built-in CiviCRM format for Avery 5395 with values: {"name":"Avery 5395","paper-size":"a4","metric":"mm","lMargin":15,"tMargin":26,"NX":2,"NY":4,"SpaceX":10,"SpaceY":5,"width":83,"height":57,"font-size":12,"orientation":"portrait","font-name":"helvetica","font-style":"","lPadding":3,"tPadding":3} to those specs (http://www.onlinelabels.com/Templates/OL5030-template-microsoft-word.htm) see what value correspond to what dimension. It was absolutely impossible to find the same information on Avery website.

So from my patched knowledge, the translation would be:
'name' => '5395' // name of label
'paper-size' => 'a4' // paper size
'metric' => 'mm' // units
'lMargin' => 15 // left margin in mm (because metric = mm)
'tMargin' => 26 // top margin in mm (because metric = mm)
'NX' => 2 // number of items in x (left to right) direction
'NY' => 4 // number of items in y (top to bottom) direction
'SpaceX' => 10 // spacing between items in x (left to right) direction in mm (because metric = mm)
'SpaceY' => 5 // spacing between items in y (top to bottom) direction in mm (because metric = mm)
'width' => 83 // width of one item in mm (because metric = mm)
'height' => 57 // height of one item in mm (because metric = mm)
'font-size' => 12 // font size
'lPadding' => 3 // left padding in mm (because metric = mm)
'tPadding => 3 // top padding in mm (because metric = mm)

Kasia

Wow, that's fantastically helpful, thank you. Armed with this I can get stuck in to making some new label formats for my sites and then, with a little experience under my belt I'll be able todo some work on the documentation for this.

Thanks again.
Graham