Company
October 16, 2023
Key Takeaways
Challenge coins have become more popular over the past several years. Many organizations hand them out for events and as mementos, among other reasons.
Challenge coins are made by creating a custom design, then transferring this design to a metal die to cast the coin. Next, the design is stamped on the metal die, making a raised image and text. Then the coins are plated, colorized (if needed), and polished.
Challenge coins are a great way to remember an event or celebrate a victory. They are also great souvenirs and are sure to stand the test of time. As a company specializing in creating memorable coins and pins, we know these make an excellent addition to any collection. Keep reading to learn more about the unique process of making challenge coins and tips for creating the perfect design for a challenge coin project.
Challenge coins are small metal tokens commonly used to commemorate a particular event or symbolize membership in a specific group or organization. The tradition of carrying them dates back to the First World War. American soldiers would carry challenge coins to prove they were unit members.
One story goes that a wealthy American officer had medallions made for his unit and gave them to his soldiers as a symbol of brotherhood. According to the story, one soldier was captured and taken prisoner but escaped and returned to American lines.
However, he was challenged by a guard who did not believe he was a member of the American military. The soldier pulled out his medallion, and the guard recognized the unit logo, allowing him to pass.
Today, members of military units, law enforcement agencies, and other organizations often carry challenge coins to prove they belong to the agency. They have become popular as collectible items and to commemorate special events and milestones.
We specialize in custom coins for individuals, organizations, and businesses.
All you need is an idea for a design and the willingness to invest in the production process.
Then, with our help, you can create a unique, custom challenge coin you will be happy to award someone or keep for yourself.
Challenge coins will typically be shipped out in 15 days or less. Of course, if for some reason we cannot get them to you in this timeframe, we will work with you to ensure the coins arrive in time for when you need them.
But as always, plan ahead and submit your order as soon as possible for the best experience!
No, we typically produce batches starting at 50 coins, but we are happy to work with you no matter how many custom challenge coins you need. Of course, the more you need, the less each coin will cost to produce. These savings are passed on to you.
For example, if you need 100 size two coins, we sell them for a base price of $5.17. But if you order 1000 of the same coin, they will cost $3.76.
Suppose you are still determining what you need or how many to order, no problem. Our team is here to help and will send you a free quote.
The most common metals in challenge coin production are brass, pewter, zinc, and iron. Sometimes an alloy of these metals is used depending on the requirements. Most modern coins are not made from precious metals but are plated with them.
We offer plating in gold, antique gold, silver, antique silver, black nickel, bronze, antique bronze, copper, and antique copper.
Like other coins, making challenge coins requires a lot of heat and metal. The challenge coin minting process beings with the design and ends with a beautiful coin you will love to own and show off.
Perhaps the most important step is the first, the design. The challenge coin’s design should reflect the coin's meaning while being easy to understand. Here are some tips for designing the perfect challenge coin:
Now that the challenge coin design has been finalized, the mold or die is created with the help of CAD or Computer-Aided Design software.
Next, the image is loaded into the CAD software, which makes a blueprint that can be read by the CNC (Computerized Numerical Control) machine.
This machine reads this blueprint to mill an inverse image of the coin's design into a steel die. This is done for both sides of the coin.
Once the die has been finished, it is tested to ensure the images transfer to the blank properly. Then, the die is tempered to ensure that it is strong enough to endure the stamping process.
It is time to stamp the image onto the blank coin using the dies. This process not only imprints an image onto the coin but also adds the raised design elements. This gives the blank the depth and dimension it needs to transform into a beautiful challenge coin.
The blank is positioned properly and pressed with tremendous pressure between the two dies, ensuring the image transfers evenly and deep enough.
The striking is done several times to make sure the design looks correct and to guarantee the proper depth of the image.
A cool feature of challenge coins is the custom coin edge that you can add for additional uniqueness. The edge is either part of the die or is added after based on the intricacy of the design.
Some popular edges are Oblique Line, Bevel Cut, Diamond Cross Cut, and Spur Cut. Each has a different look and feel and can complete the design beautifully.
After completing all the cutting and stamping, the coin goes through a polishing and deburring process. First, the edges of the coin are deburred to remove any sharp edges created during the die-striking process.
Deburring ensures that the edges of the coin are smooth and safe to handle, as these edges can be extremely sharp and dangerous.
Next up is polishing. Polishing the coin can be done with buffing wheels and compounds to remove any surface imperfections and give the coin a shiny finish. The type of polishing compound used will depend on the metal used for the coin and the finish you need.
For example, a rouge polishing compound is commonly used to polish brass and other yellow metals, while a white diamond compound is used to polish stainless steel and other white metals.
Polishing can also be done by tumbling the coins in a barrel with abrasive media. This method can be used for bulk orders and is a more efficient way to polish large quantities of coins.
Regardless of the method used, polishing helps protect the coin from tarnishing and other forms of corrosion, which can damage the surface over time.
Plating a custom challenge coin is a big part of the coin design process. The coin cannot be made entirely of a precious metal like gold due to the cost of the metal.
Instead, the coin is made from more common metals like zinc and iron and a tin layer of silver, gold, nickel, bronze, or copper as applied after.
These coin plating options provide a unique look and feel; the type of metal used will depend on the desired appearance and budget for the coin.
The process is typically done via electroplating. The process starts by immersing the coin in a solution containing metal ions that will be used for plating. The coin serves as the cathode, and a piece of metal that serves as the anode is also immersed into the solution.
An electrical current is then applied, causing the metal ions in the solution to be attracted to the coin's surface. The metal ions bond to the coin's surface, forming a thin layer of metal covering the entire coin.
Some people may see the challenge coin plating process as an unnecessary step. However, there are several reasons why you should not skip it.
Absolutely! Dual plating allows for the creation of challenge coins with two different metal finishes, adding depth and visual interest to the design.
For example, a challenge coin can be dual-plated with a brass base and a silver outer layer, giving it a unique look that combines the warm tones of brass with the shine of silver.
One optional step is the texturing of the metal. Not all coins are made perfectly smooth and glossy. Look at the change in your pocket. Some coins have multiple textures to make specific elements pop from the rest of the design.
Depending on the required finish, these are done at different stages of the challenge coin production process.
A cool addition to any challenge coin is adding color. While not required, it can add depth to the images and provide a unique look to an otherwise bland metal coin. This can be done in a few different ways: desired look, metal, and image depth.
Another step, if the design calls for it, is the laser engraving process. Lasers are used to etch an intricate design onto the challenge coin that may not have transferred over during stamping. It is typically used for adding text and other fine details.
Lasers can also add custom text to the edges of the coin, enhancing the custom challenge coin’s look. This step is typically done after plating, as the lasers do not damage the added metal.
With the other steps complete, it is time to finish the coin. We thoroughly check the coin to ensure the image is clear, the edges are smooth or cut to the requested design, and the color is bright.
Once the inspection is complete, we add a layer to protect the coin further. This is not mandatory, as the coating will cover some textures added to the coin.
An epoxy coating is a clear, protective layer applied to the coin's surface. This coating protects the coin from scratches, fading, and other damage and gives it a high-gloss appearance.
A clear resin coating is another protective layer we can apply to challenge coins. This coating gives the challenge coin a glossy and smooth appearance while protecting it from scratches and other damage.
A high-gloss lacquer coating gives the custom challenge coin a shiny and reflective appearance while protecting it from damage.
Finally, the coin is packaged and ready to ship to you. Again, quality control is vital, and we do not send any coins that do not meet our standards.
