Any of the Nexgen series of chips will take a 1" label, it's not limited to the RPT set. That having been said, you can get a real bargain on RPT chips by buying them in multiples of 200 chip quantities,
http://www.5stardeal.com/deals/10Exp...=10-8100-2002c
Insofar as labels are concerned, you'll want a 1" label.
Plan on using a 7/8" (.875) print area, as computer printers will shift the printed image a bit from page to page (at .18 to .60 per page for the labels); don't expect every page to be perfectly centered. So you'll want to move the text in a bit. As for the text, it's best to use a font that is easily read at small font sizes and you'll want to use at least 6 or 8 pt. fonts, though some fonts like Arial Black are still readable at 4 pt.
To get a realistic view of how the image will actually appear on a chip, size the chip image to about 39-40mm and then size the inlay to 1" at whatever resolution your printer will print at, then print out the images on your printer. If you're using a raster image (as you will with photos), try saving it in a TIFF format at no less than 300 DPI, 600 may be better depending on the image (use the maximum resolution that your printer is actually capable of, not the interpolated resolution that the manufactuer may advertise). TIFF does not compress and interpolate the image like JPEGs will, however the downside is that you can end up with huge file sizes for a 1" image (over 1 MB for a flattened image, 5+ MB for an unflattened image.