We are aware of the issue with the badge emails resending to everyone, we apologise for the inconvenience - learn more here.
Uploading the zipped file to dropbox and unzipping it inside would save a lot of time and traffic for users. Some of the web services already exist for that (like this one http://www.quora.com/Is-the...
They really need to vet going on this. 3d printing is difficult to do without it