Not sure if this counts as new info, but figured I'd share, just in case:
I called
D23 this afternoon to check on my missing Saturday badge. The rep told me that the badges are being shipped out in batches (apparently by day and type), and they're still in the process of sending them out. Having said that, she noticed my missing badge didn't have shipping info attached.
She didn't explicitly say it, but it sounds like they know they've got an issue. They may have already said this somewhere, but they're going to have Will Call available on the 7th and 8th at the Anaheim Hilton (I think she said it starts at 9am) for people to get replacement badges in advance if they don't receive them before the event (then at ACC on the days of the event).
She also confirmed that the Honda Center passes will be emailed separately.