I always pick up my badge on Thursday, and the wait time is pretty all over the place. I came over after work last year, probably around 6 or 7pm and the wait was 45 min-1 hour if I recall.
I recommend early afternoon on Thursday, if you can
Those of us that live in Seattle and can't take a day off for Thursday will likely be coming to pick up after work. Hence why the wait around rush hour (5-7pm) might be longer.
 Oops, didn't realize this is from last year.