Related reading: specification guide · MOQ, lead time and pricing · quality control process · full product catalog
Before you request a quote, this specification guide maps out every choice that changes how a soft enamel pin, hard enamel challenge coin or die struck medal looks, feels and wears. Use the tables below to shortlist options, then send us your artwork and requirements.
1. Base metal options
The base metal drives weight, detail sharpness, cost and how well the piece takes plating.
| Base metal | Detail & feel | Typical use | Relative cost |
|---|---|---|---|
| Iron / steel | Good detail, higher weight, magnetic | Lapel pins, budget coins, souvenir medals | Lowest |
| Zinc alloy | Excellent fine detail, takes 3D relief well | 3D pins, dimensional coins, keychains | Low to mid |
| Brass | Crisp edges, premium heft, warm base tone | Hard enamel pins, military and police coins | Mid |
| Copper | Very crisp for thin lines, soft, patinas quickly | Cloisonné style enamel pieces | Mid to high |
| Stainless steel | Hard wearing, tarnish resistant, no plating needed | Outdoor and industrial badge work | High |
2. Colour processes compared
| Process | Surface | Durability | Best for |
|---|---|---|---|
| Hard enamel (cloisonné) | Polished flush to metal lines, glass smooth | Highest — colours will not sink or scratch away in normal wear | Premium pins, corporate and military coins |
| Soft enamel | Recessed colour with raised metal edges you can feel | High — colour sits below the metal line | Most custom pins and art designs |
| Offset / screen print | Flat printed detail on metal | Medium — usually finished with epoxy if exposed | Gradients, photographs, tiny text |
| Epoxy dome | Clear resin layer over printed art | Medium — resin can yellow in prolonged UV exposure | Promotional pins, keychains, bottle openers |
| Glitter / glow / translucent | Speciality enamel variants | Same base as the host enamel process | Trend pieces and event merchandise |
3. Plating finishes
Standard finishes include shiny gold, silver, nickel, black nickel, antique gold, antique silver, antique bronze, copper, matte gold and matte black. Two-tone and dual plating (for example polished gold against antique silver) add contrast but require masked polishing, so allow extra time when you plan the schedule.
4. Size and thickness guide
| Product type | Common range | Recommended thickness | Notes |
|---|---|---|---|
| Lapel pin | 0.75–1.5 in (19–38 mm) | 1.2 mm standard, 1.5 mm for larger badges | Below 0.75 in fine text becomes hard to read |
| Challenge coin | 1.5–2 in (38–50 mm) | 2.0–3.0 mm | Heavier coins read as higher value in hand |
| Medal | 2–3 in (50–76 mm) | 2.0–3.0 mm | Check ribbon lug or slot strength above 3 in |
| Keychain / bottle opener | 1.5–3 in | 2.0–3.0 mm | Thin out sections weaken opening mechanisms |
5. Tolerances and limits worth agreeing up front
The tolerances below are the practical working limits for die struck and die cast work. Agreeing them in writing before tooling starts is what prevents most disputes later.
| Item | Practical tolerance | Why it matters |
|---|---|---|
| Overall dimensions | ±0.2 mm (die cast), ±0.1 mm (die struck) | Keeps badges fitting existing mounts and cases |
| Minimum metal line width | 0.3 mm (approx. 0.85 pt) | Thinner lines break in polishing or wear away |
| Minimum text height | 1.2 mm cap height | Below this most fonts lose legibility in enamel |
| Colour match | Pantone Solid Coated reference, judged in a D65 light booth | Screens and home printers shift colour badly |
| Plating thickness | Measured by XRF at agreed micron ranges | Thin plating wears through at high points first |
| Flatness | Agree application — display pieces versus wearable badges | Large coins and medals bow slightly during firing |
6. Backing and attachment choices
| Fitting | Holds | Best for |
|---|---|---|
| Rubber clutch | Light to medium pieces, no teeth damage | Fashion pins and retail packs |
| Butterfly (military) clutch | Firm hold, low profile | Uniform pins and daily wear |
| Safety pin / locking pin | Secure on thick fabric | Uniforms, backpacks, sashes |
| Magnet backing | No hole through fabric | Suits and delicate clothing |
| Keyring, chain or tie tack | N/A | Keychains, dog tags, formal wear |
7. Artwork files that tool cleanly
- Supply vector files — AI, EPS or PDF — with all fonts converted to outlines.
- Keep metal lines at 0.3 mm or thicker and lettering at 1.2 mm cap height or larger.
- Name every colour against a Pantone Solid Coated code instead of relying on screen colour.
- Send layered files so plating areas stay separate from enamel fills.
- Include cut shape outlines for custom silhouettes, plus a marked 3D/2D note if you want relief.
Need help drawing it? Our step-by-step walkthrough covers both Illustrator and Photoshop workflows, starting from how to design enamel pins.
Frequently asked questions
Which is better, hard enamel or soft enamel?
Hard enamel is ground flush and polished for a jewellery-like finish, so it costs more and suits premium or long service pieces. Soft enamel keeps visible metal ridges and suits most artwork, especially detailed illustrations. See the side-by-side comparison in hard versus soft enamel pins.
Can a design include gradients or photographic detail?
Yes, but those areas move from enamel to printing. We combine soft enamel for the solid shapes with printed detail for gradients, usually sealed under an epoxy dome.
How thin can the metal lines be?
Keep every metal line at 0.3 mm or thicker. Anything thinner tends to break away during polishing and is the single most common cause of re-tooling.
Will the colour match my screen?
Digital screens vary widely. We match against Pantone Solid Coated references and check the fired sample in a standard light booth, so please give Pantone codes on the artwork.
Do I need a different file for 3D designs?
Yes. 3D relief needs a depth map or clear shading notes in addition to the flat artwork, and it changes tooling time. Browse examples under 3D pins.
What should I do about sizing if the piece has to fit an existing case?
Give us the internal case dimension and we will tool the piece to the agreed tolerance, then confirm on the first article sample before the full run.