Views: 0 Author: Site Editor Publish Time: 2025-08-20 Origin: Site
Have you ever held a coin that tells a story? Challenge coins do more than shine—they represent unity and pride. From military honors to corporate gifts, their meaning is timeless. But how are these special coins actually made?
In this post, you'll learn the detailed steps behind creating these delicate challenge coins.
A design starts simple, but it carries meaning. Many coins include insignia, mottos, and special text. Others highlight important dates or locations that matter to a group. Logos and symbols often appear too, because they instantly connect the coin to its purpose. A military coin may feature a unit emblem, while a company coin might show its logo. An event coin can display an image tied to the occasion. The design should reflect why the coin exists and who it represents.
Size is more than a number. Standard coins often measure between 1.5 and 2 inches, making them easy to carry. Some people prefer larger coins around 2.5 inches or more, since extra space allows more detail. Smaller coins, about 1 inch, are practical but may limit artwork. Thickness matters as well. At 3 millimeters, a coin feels solid but light. At 4 millimeters, it becomes heavier and more premium. Shape also changes how a coin feels in the hand. Round coins remain the most common, yet shields, state outlines, or even mascot shapes stand out. Some designs add function, like a coin cut into a bottle opener, combining style and use in one piece.
A mold is where the coin begins to take shape. It starts when artwork is converted into a digital file using CAD software. The design is then moved into CAM, which guides CNC milling machines. These machines cut into a steel block and create the negative impression of the coin. Once the molds are cut, they are tested by striking soft metal to check clarity. If flaws appear, adjustments are made before moving forward. After the design looks right, the molds are heat-treated in an oven. They are then cooled in oil to harden the steel, so it can handle the pressure of stamping coins again and again.
There are two main ways to bring a mold into action. Die striking is the older method. It uses a press to stamp brass blanks, which gives a sharp and traditional look. Many collectors prefer this style because it feels weighty and durable. Die casting works differently. It uses molten metal poured into a compound mold, capturing very fine detail. It can handle 3D surfaces, deep layers, and even cutouts that striking cannot manage easily. Die striking costs more because brass and shipping are heavier, but the quality feels premium. Die casting is more affordable and flexible, yet it can lack the dense feel of brass. Each method gives coins their own character, and the choice depends on the design and budget.
Once the mold is ready, it's time to strike the coin. This part uses serious pressure—between 500 and 1000 tons—to press the design into the metal. Most round coins start from blanks, which are flat discs punched from a brass strip. These blanks go between the top and bottom molds, and the press stamps the artwork in one strong motion. For custom-shaped coins, the process looks different. Instead of cutting blanks first, the design is struck directly onto long brass strips. After that, each coin is cut out using a custom-shaped cutter made through a Wire EDM process. This cutter matches the shape of the design perfectly, even if it's something like a badge, mascot, or bottle opener.
Edges may seem like small details, but they really affect the coin's feel and look. After striking, coins often get rough edges. That's when the cutting process begins. Some edges, like rope or diamond-cut, are done by hand using a rotary table. As the table spins, the edge is shaped one coin at a time. Others, like reeded or petal edges, may be added during stamping or with special tools. Here are a few common edge styles:
Standard: smooth and clean
Rope: twisted look, traditional style
Petal: sharp, bold angles
Reeded: fine grooves, like a regular coin
Spur-cut: jagged texture
Diamond-cut: crisp lines that reflect light
Bevel-cut: angled rim for added depth
Each option adds character and can change how the coin is held or displayed.
After coins are struck and cut, they aren't quite ready to show off. The edges can be sharp, and the surface might feel rough. That's where polishing and deburring come in. These steps smooth out ridges, remove burrs, and help the coin feel finished in your hand. For smaller orders or intricate coins, polishing by hand with a soft cloth works best. It gives close control and a personal touch. But for larger batches, machines are faster. Coins can tumble in dry media or spin inside a mix of water, soap, and small stones. This process gently rubs the metal clean without changing the design.
Once the coin is smooth, it needs a finish. This changes how it looks and how it catches the light. A high-gloss finish creates a shiny, mirror-like surface that's great for modern or high-impact designs. It's especially popular for corporate gifts or commemorative awards. If the goal is a vintage or ceremonial feel, then a matte or antique finish works better. These finishes dull the shine slightly, adding depth and texture. They work well for military coins or traditional themes. Whether it's polished by hand or machine, the right finish helps the coin stand out and last longer.
Plating gives each coin its final tone and surface. It changes how the coin looks, feels, and lasts. You can choose bright finishes like gold, silver, nickel, or copper. These give the coin a sharp, clean appearance. For something bolder, black nickel or rainbow metal creates a more modern or flashy effect. If you want a classic or aged style, antique finishes work better. Antique gold, bronze, copper, or nickel offer a muted tone. They also help raised details stand out without adding color. These finishes are often used on military, law enforcement, or legacy coins.
Once coins are polished, they go through electroplating. Each coin hangs from copper wire before being dipped into different chemical baths. The process begins by cleaning the metal, so no dirt blocks the coating. After that, the coins enter a bath filled with metal particles. When we run an electrical current through the liquid, the metal sticks to the coin surface. It forms a thin, even layer that bonds tightly. We can even apply more than one layer if needed. This adds depth, shine, or texture while protecting the coin from wear, tarnish, or corrosion.
Color gives coins personality and helps certain parts stand out. One common method is soft enamel. This fills recessed areas with paint, leaving raised metal lines between each color. It gives a textured feel and works well for bold designs. Hard enamel, also called imitation hard enamel, is a bit different. The enamel overflows slightly, then gets polished flat. That makes it smooth and very durable. For high-resolution photos or complex images, offset digital printing works best. It prints the design directly onto the coin surface with clear detail. Some coins also get an epoxy resin coating. This clear layer covers the entire surface, locking in the color and adding extra shine and protection.
The timing depends on the enamel type. For soft enamel, color comes after plating. The reason is simple—the raised metal borders need to stay clean and shiny. For hard enamel, the colors go on first. After curing, each layer is ground down and polished smooth. Then the coin gets plated. That order keeps the metal finish intact and ensures a flat, seamless surface. Knowing when to add color helps avoid design issues and makes sure the finish turns out right.
Engraving adds a final touch that makes each coin feel one-of-a-kind. It's usually done after plating and coloring, when the surface is smooth and ready. A laser carefully burns markings onto the coin without affecting the finish. This method works well for serial numbers, personal names, or unit codes. You can place engraving along the coin's edge or across the flat surface, depending on the design. It's a fast and precise process, perfect for limited editions or award pieces where each coin needs to say something unique.
Not all challenge coins stop at metal and color. Many designs push things further with fun or useful features. Glow-in-the-dark enamel adds visibility in low light and a cool surprise in the dark. Rhinestones can bring sparkle and contrast to specific parts of the coin. Some coins even include a rotating center, adding movement and playability. If you want function with form, a bottle opener cutout is a clever addition. This makes the coin not only symbolic but also useful. These features help coins stand out at events or become lasting keepsakes people want to show off.
Before any coin gets shipped, it goes through one last check. The team looks closely for problems like rough plating, color that doesn't match, or details that appear blurry. They compare each coin to the approved proof to spot issues early. If something looks off, they don't just toss it. Some coins get re-polished, while others may be re-struck to fix design flaws. This stage matters most for limited editions, awards, or coins meant to leave a strong impression. Even a small scratch or color smudge could mean the difference between a keepsake and a reject.
Once a coin passes inspection, it gets packed up for delivery. The packaging can be simple or custom, depending on your style or budget. Basic plastic pouches work fine for casual giveaways or large orders. For something more polished, velvet drawstring bags offer a soft, elegant feel. Leather pouches raise the bar even higher, great for formal events or corporate gifting. If the coin is meant for display, a custom presentation box makes the biggest impact. It protects the coin and highlights its importance the moment someone opens it. People remember how a coin looks—and how it's presented.
Before you sketch anything, take a moment to ask yourself why the coin exists. Is it to reward service, mark an event, or unite a team? Knowing the purpose helps guide every design choice. Then, think about who will receive it. Military members, employees, or customers all expect different tones. A formal coin might need clean lines and antique finishes. A fun giveaway could use bold colors or custom shapes. You should also ask how you want it to feel in someone's hand. Do you want it sleek and premium, or simple and lightweight? That decision will impact size, thickness, and finish.
You don't need to be an artist to bring your coin idea to life. Many manufacturers offer professional design support at no extra cost. Just send in a rough sketch or even a short description, and their team will help you build a visual proof. They also guide you on choosing the right materials, plating, and edge styles. Another bonus is flexibility. Today's suppliers let you order small quantities—sometimes as few as 50 coins. Turnaround times are fast too, often within a few weeks. This makes it easy to test designs, prepare for events, or create limited editions without long delays.
Making challenge coins is both creative and technical. From the first sketch to the final polish, each step counts. A well-made coin shows pride, builds unity, and celebrates achievements. Our company provides three types of challenge coins, including soft enamel challenge coins, hard enamel challenge coins and 3D challenge coins, welcome to pick.
Brass is popular for its weight and premium feel, while zinc alloy is more affordable and flexible for complex designs.
Yes, you can choose shapes like shields, mascots, or even bottle openers using custom cutting molds.
Production usually takes 3–6 weeks, depending on the design complexity and quantity ordered.
Soft enamel sits below metal borders for a textured look. Hard enamel is polished flat and more durable.
Some manufacturers offer low minimums starting around 50 coins, ideal for small teams or limited editions.
