Challenge Coins — The Manufacturing Process

1. DESIGN & ARTWORK
   The process starts with a concept sketch or digital design. Artists create detailed artwork specifying shape, size typically 38–50 mm), thickness, and any custom elements like cutouts or spinning parts.
2. DIE STRIKING (MOULD CREATION)
   A steel die (mould) is engraved — either by hand or CNC machine — based on the approved design. This die is the master template used to stamp the coin’s shape and relief details.
3. BLANKING
   Metal sheets (usually brass, zinc alloy, or copper) are cut into blank discs or custom shapes using a punch press. These blanks are sized to match the final coin dimensions.
4. STAMPING / STRIKING
   The blank is placed between the dies and pressed under high tonnage pressure (often 100+ tons). This imprints the design in raised or recessed relief onto both sides of the coin.
5. TRIMMING & EDGE WORK
   Excess metal is trimmed and the edges are finished. Common edge treatments include rope, reeded (ridged), satin, or flat finishes. Some coins get a custom engraved or cut-out edge.
6. POLISHING
   Coins are tumbled in a polishing machine with abrasives to smooth rough edges and create a uniform surface finish, preparing them for plating.
7. PLATING / METAL FINISHING
   Coins are electroplated with the desired metal finish — common options include gold, silver, nickel, brass, antique bronze, or black nickel. This gives the coin its final metallic appearance.
8. SOFT ENAMEL OR HARD ENAMEL FILLING (if applicable)
   For coloured coins, recessed areas are hand-filled with enamel paint. Soft enamel leaves a textured feel (paint sits below the metal edges), while hard enamel is baked and polished flush for a smooth, durable finish.
9. EPOXY COATING (optional)
   A clear epoxy dome can be applied over the surface to protect the design and give a glossy, glass-like appearance — especially useful for intricate or photo-printed designs.
10. QUALITY INSPECTION
    Each coin is inspected for defects in stamping, plating, enamel fill, and overall finish. Rejected coins are melted down or reworked.
11. PACKAGING & SHIPPING
    Approved coins are packaged individually (often in velvet pouches, plastic capsules, or display boxes) and shipped to the customer.

The entire process — from design approval to delivery — typically takes 2 to 4 weeks for standard orders, notwithstanding peak commemorative, posting or deployment periods..