I've been doing my own labels for my Cattery sets since the PGI 8Vs dropped... and they turn out fairly well.
For the PGI 8Vs, my current tech is OnlineLabels.com's weatherproof vinyl 1.1" label (OL1171). I've been experimenting with various spray laminates for these because I don't have access to a Cricut, and I've gotten the best results with Krylon's Triple Thick glaze. They're clearly not anywhere close to Gear's quality (they're just precut labels printed on a Canon Pixma 3260G or w/e it is, the megatank one), but they work & the laminate ends up at the right thickness to protect the label without creating spinners. This is the best I can do when I don't have a bankroll to spend on Gear.
I create the art in Photoshop and use OnlineLabels' Maestro to generate PDF print sheet files, then print them from Acrobat Pro (because browser PDF readers will fuck up the margins and fuck up alignment to no end and ruin labels that cost $1.75 a sheet).
The downsides of course are that if OnlineLabels doesn't make the label size you need for your chip, you'll need to forget this idea and order your labels from Gear or StickerMule. Also, it's very easy for the spray laminate to look like shit, especially if it's windy or humid when you're spraying, so it's tough to get that exactly right.