Related reading: specification guide · MOQ, lead time and pricing · quality control process · full product catalog
Custom metalwork fails in predictable places: colour drift, thin plating on high points, soft detail after polishing, and fittings that loosen in wear. This page documents the control points we use to catch those failures before shipping. Questions about finish options are answered in the specification guide.
Incoming material control
- Base metal verified against the specification before tooling — alloy grade, sheet thickness and hardness.
- Enamel and plating chemistry checked for batch codes and shelf life, since aged enamel shifts colour after firing.
- Fittings sampled for spring tension and plating condition on arrival.
Tooling and striking control
| Check | Method | Frequency | Failure it prevents |
|---|---|---|---|
| Die condition | First-off inspection and periodic re-check during the run | Start of run, then per shift | Soft detail and rounded edges as the die wears |
| Line width retention | Comparator against the approved drawing | Start of run, then per shift | Broken or missing metal lines |
| Dimensions | Calipers against tolerance (±0.2 mm die cast) | Per sampling interval | Pieces that no longer fit cases or mounts |
| Flatness | Flat plate check | Per sampling interval | Bowed coins and medals |
Plating control
| Check | Method | Why it matters |
|---|---|---|
| Thickness | X-ray fluorescence (XRF) gauge at agreed micron ranges | Thin plating wears through first at raised points |
| Adhesion | Tape and bend testing per standard practice | Catches plating that will peel in service |
| Appearance | Comparison against the approved master under standard lighting | Keeps antique finishes and two-tone masking consistent batch to batch |
| Corrosion resistance | Salt spray testing where the end use requires it | Relevant for outdoor and marine applications |
Colour control
- Every enamel colour is referenced to a Pantone Solid Coated code on the artwork.
- Fired colour is judged in a D65 standard light booth, never under office lighting or on a screen.
- An approved master sample is retained for comparison on the bulk run and any reorder.
- Colour count is confirmed against the artwork before each fill stage begins.
Final inspection and packing
Packing is where most cosmetic damage happens, so it is treated as part of inspection rather than an afterthought.
- AQL sampling against ISO 2859-1 levels agreed at quotation, with cosmetic and critical defect classes separated.
- Fitting function tested on the sampled units — clutch engagement, magnet pull, ring closure.
- Individual protection for hard enamel and polished faces to prevent surface-to-surface abrasion in transit.
- Carton weight and count verified before collection, with photos retained for the order record.
Frequently asked questions
How do you keep colour consistent between batches?
Colour is referenced to Pantone numbers, verified in a standard light booth, and every order keeps an approved master sample that reorders are matched against.
What if some pieces in the box are faulty?
Sampling follows agreed AQL levels, but if you find defects above the agreed classes, send photos and batch codes — the refund and returns policy explains how claims are handled.
Can plating thickness be specified?
Yes. Give the micron range you need at quotation and we will verify it by XRF rather than relying on bath time alone.
Will the finish survive outdoor use?
For marine or outdoor service, specify stainless steel or a heavier plating plus testing, and avoid epoxy domes which can yellow under prolonged UV exposure.
Can I see inspection results before shipping?
Yes — request sample photos and the inspection record with your order and we will send them for approval before the cartons leave.