From Concept to Strike — Crafted With Precision
A custom challenge coin is more than metal.
It is a permanent symbol of identity, achievement, and recognition.
At Challenge-Coins.com, we guide you through every stage of the process — from initial artwork to final strike, finish, and presentation — ensuring your coin is engineered with intention and manufactured to the highest standard.
Below is a complete overview of how custom challenge coins are designed and produced.
1️⃣ Defining the Coin: Size, Shape & Structure
Every project begins with foundational specifications.
📏 Size Options
Standard challenge coin sizes range from:
• 1.5” (classic military size)
• 1.75” (most popular modern size)
• 2” (bold presentation size)
• 2.5”+ (executive or commemorative display pieces)
Larger coins allow for:
- Greater 3D depth
- More detailed artwork
- Stronger physical presence
- Heavier weight
Thickness typically ranges from:
- 3mm (standard)
- 4–5mm (premium weight)
- 6mm+ (executive heavy strike)
Weight and thickness directly affect how the coin feels in hand — and perceived value.
🔷 Custom Shapes
Coins do not need to be round.
Custom shape options include:
- Shields
- Dog tags
- Badges
- State outlines
- Unit insignia silhouettes
- Fully custom die-cut shapes
Structural planning ensures durability even in complex cutouts.
2️⃣ Artwork Development & Approval
🎨 Initial Concept
You may provide:
- A logo
- A sketch
- A reference coin
- A written idea
- Or request a fully original design
Our design team creates a digital proof that shows:
✔ Front and back layouts
✔ Text placement
✔ 3D depth mapping
✔ Enamel color separation
✔ Edge style
🔄 Artwork Revisions
Before production begins:
- You receive a full-color digital proof.
- Revisions are made until approved.
- Metal lines are adjusted for strike feasibility.
- Enamel sections are separated properly.
Approval at this stage locks in design layout and direction.
3️⃣ 3D Rendering & Die Engineering
For sculpted or high-relief coins, we move into engineering phase.
🧱 3D Modeling
If your coin includes:
- Sculpted faces
- Detailed scenes
- Topographical textures
- Deep dimensional relief
A 3D render may be created to simulate:
• Depth levels
• Raised vs recessed metal
• Shadowing and contour
• Final metal appearance
This ensures realism and manufacturability.
🛠 Die Creation (Tooling Stage)
Once artwork is approved:
- Steel dies are engraved using CNC or precision engraving.
- The die is hardened for repeated striking.
- Depth mapping is calibrated for consistent relief.
At this stage, adjustments are no longer cosmetic — they are structural. Approval before die production is critical.
For premium projects, die previews or render confirmations may be provided.
4️⃣ Metal Selection & Finishes
The finish defines personality.
✨ Plating Options
• Antique Brass
• Antique Silver
• Antique Copper
• Polished Gold
• Polished Silver
• Black Nickel
• Dual Plating (two-tone)
• Matte / Mirror combinations
Antique finishes emphasize depth.
Polished finishes highlight contrast and authority.
🎨 Enamel Types
Soft Enamel
- Textured metal edges
- Color sits slightly recessed
- Traditional military look
Hard Enamel
- Smooth polished surface
- Jewelry-like finish
- Higher-end presentation
Specialty options may include:
- Glow-in-the-dark enamel
- Translucent enamel
- Glitter enamel
- UV printed details
5️⃣ Edge/Rim Options
Edges elevate the coin beyond basic design.
Options include:
• Standard flat edge
• Rope edge
• Diamond cut edge
• Oblique line edge
• Spur edge
• Custom engraved edge
• Sequential numbering
Edge detailing adds subtle prestige.
6️⃣ Special Features & Add-Ons
For high-impact coins, consider:
🔢 Sequential numbering
🖋 Edge text engraving
🧲 Hidden magnets
🔄 Spinner center coins
🔓 Cut-outs or negative space
🖼 Epoxy dome coating
🪖 Bottle opener backs
🧷 Belt clip or display stand integration
Each feature must be engineered during die stage planning.
7️⃣ Production & Striking
Once dies are complete:
- Metal blanks are cut.
- Coins are struck under high pressure.
- Edges are trimmed and polished.
- Plating is applied.
- Enamel colors are filled and cured.
- Surface polishing and inspection occurs.
Quality control ensures:
- Clean metal lines
- Consistent enamel fill
- Proper color matching
- Accurate depth
8️⃣ Final Inspection & Packaging
Before shipment:
✔ Coins are individually inspected
✔ Numbering verified (if applicable)
✔ Finish consistency checked
✔ Surface imperfections reviewed
Presentation options include:
📦 Poly bags (standard)
🎁 Velvet pouches
🗃 Acrylic capsules
📘 Display cases
🎖 Custom printed presentation boxes
Premium packaging elevates executive or commemorative coins.
9️⃣ Delivery & Distribution
Production timelines vary by:
• Size
• Complexity
• Source
• Quantity
• Finish type
Rush options may be available for certain builds.
Once completed, coins are securely packaged and shipped to your location.
🔟 From Start to Finish — The Process Summary
- Consultation & Specification
- Artwork Development
- Revision & Approval
- 3D Rendering (if required)
- Die Engineering & Tooling
- Metal Striking
- Plating & Enamel
- Inspection
- Packaging
- Delivery
🏛 Why Detail Matters
The difference between a basic coin and a legacy coin lies in:
⚖ Weight
🧱 Depth
✨ Finish
📐 Precision
🔩 Edge detailing
📦 Presentation
A well-engineered challenge coin will still look powerful twenty years from now.
👑 Commission With Confidence
Whether you are designing:
🎖 A military unit coin
🚓 A command staff recognition piece
🏢 A corporate leadership coin
🎉 A commemorative event coin
🔒 A limited Private Mint release
We guide you through each technical stage so your final coin is not just approved — but engineered for permanence.