Challenge coins are made through a multi-step manufacturing process that turns a finalized design into a struck, plated, and finished metal coin. From creating steel dies to enamel coloring and final inspection, each step affects the coin’s appearance, durability, and overall quality.
I will explain to you the process of making challenge coins step-by-step.
Step 1: Creating the Challenge Coin Design
The first step in making challenge coins is to create and finalize your custom design. You will have to define the purpose of your challenge coin: military, corporate, event, or organization. For your design, you will have to decide if it’s single-sided or double-sided.
After, you must choose their size and thickness. You will have to select the 2D or 3D elements of the design and finalize logos, texts, dates, and symbols.
From Artwork to CNC Programming
Your final artwork is converted into CAD/CAM files. Technical details such as size, depth, thickness, and tolerances are set so the design can be engraved into steel dies.
Step 2: Creating the Steel Mold (Die)
CNC Engraving the Die
The inverse coin design is engraved into steel using CNC machines. Test strikes are made to confirm detailed accuracy.
Heat Treating the Die
Steel dies are heat-treated so they can withstand high-tonnage striking and maintain consistent quality during mass production.
Step 3: Preparing the Metal Blanks
Metal strips or round blanks are prepared based on your chosen size and shape. The common materials you can choose from include brass, zinc alloy, and iron. The selection of material greatly affects the weight, detail, and cost of your coins.
Step 4: Striking the Design into Metal
Die Striking Process
High-pressure presses strike the steel dies into metal blanks, forming raised and recessed details and creating the coin’s primary shape.
Step 5: Cutting, Trimming, and Smoothing
Cutting Round and Custom Shapes
Round coins are punched from metal strips. Custom shapes are cut using cutting dies or wire EDM.
Deburring and Pre-Polishing
Sharp edges and burrs are removed through tumbling or hand grinding. Coins are then pre-polished to prepare surfaces for plating.
Step 6: Metal Plating and Surface Finishing
Cleaning and Surface Preparation
Coins are cleaned in chemical baths to ensure plating bonds evenly to the metal surface.
Applying the Plated Finish
Electroplating is used to apply finishes such as gold, silver, copper, or black nickel. Antique or polished effects are created at this stage.
Step 7: Adding Enamel Color
Soft Enamel Challenge Coins
Enamel is added after plating, leaving raised metal lines visible. This creates a textured, classic look.
Hard Enamel Challenge Coins
Enamel is overfilled and polished flat, creating a smooth and level surface between metal and color.
Step 8: Edge Options and Special Features
Challenge coins have edges that are made into the mold. Some common edge styles are flat edge, rope edge, and diamond-cut edge. Other optional features include laser-engraved serial numbers, names, dates, and multi-level designs.
Step 9: Final Finishing, Quality Control, and Packaging
Inspection and Quality Control
Each coin is inspected for plating quality, color accuracy, and detail clarity. Defective pieces are reworked or removed.
Packaging and Delivery
Coins are packaged in polybags, velvet pouches, or presentation boxes before final shipment.
FAQs
- Can You Make Your Own Challenge Coins?
- Yes. All you have to do is finalize your custom design and other details before sending your file to us.
- How Long Does It Take To Get Challenge Coins Made?
- The production time is usually 10-18 days depending on the quantity.
- What Are Challenge Coins Usually Made Of?
- Challenge coins are made of brass, zinc alloy, and iron.
- What Is The Purpose Of A Challenge Coin?
- The main purpose of challenge coins is to celebrate or honor a member or person by giving them a token of appreciation.
- Are You Able To Manufacture Coins In Different Shapes?
- Yes. Challenge coins come in different shapes like circles, squares, and triangles.
