I think the main delay is probably turnaround time on later prototypes. It takes a while to get something custom made, get injection molds done, get a prototype out of them, so like the idea is that she would have been working on this for 3 years, but not constantly on it for free years.
Getting anything done with custom PCBs is the same sorta design, order, wait, assemble, test, repeat process. So while it may take 50~250 hours of work to make just the electrical portion of a DEF CON badge, that 50~250 hours may take place over 6 months.