Below please find the main process types we use for making our items.

Die Struck / Stamping

For a distinguished and elegant look, look no further than a Die Struck pin without color fills. We start by creating a die with your design in it and we use this die to strike your design in a copper base metal. This process creates raised and recessed areas. The recessed areas can be textured or sandblasted to give your design depth and distinction. Finally, the raised areas are polished to a mirror like finish and your pin is than plated in Gold, Silver, Bronze, Nickel, or Black Nickel. Antique finishes can be applied for a truly unique look.

Standard Thickness: 1.2mm to 1.6mm depending on the size of your pin
Advantages: A jewelry quality pin; high perceived value; can be less expensive than many enamel filled pins.
Disadvantages: None

Die Struck Soft Enamel

This is a very traditional and economical process. We start by creating a die with your design in it and we use this die to strike your design in an iron or copper base metal. This process creates raised and recessed areas. The recessed areas are filled with enamel paints in the colors of your choice. The enamel is filled below the top level of the pin to protect the enamel while maintaining the traditional look. Finally, the raised areas are polished to a mirror like finish and your pin is then plated in Gold, Silver, Bronze, Nickel, or Black Nickel. An optional epoxy varnish can be added to further protect your pin.

Standard Thickness: 1mm to 1.6mm depending on the base metal and size of your pin
Advantages: Traditional look; low price for high quantities.
Disadvantages: Not good for highly detailed designs.

Cloisonne 

         

For unsurpassed quality and colors with unbelievable depth, there is no other choice than Cloisonne. The ancient art of Cloisonnedeveloped in China thousands of years ago is still alive at CustomMedals.biz We start by creating a die with your design in it and we use this die to strike your design in a copper base metal. We then apply ground colored glass to your pin and bake it at 1600 degrees until the glass liquefies and then hardens. Your pin is then polished to a smooth finish to reveal your hand crafted design. Finally your pin is plated in Gold, Silver, Bronze, Nickel, or Black Nickel.

Standard Thickness: 1.2mm to 1.6mm depending on the size of your pin
Advantages: A collectable jewelry quality pin; unsurpassed durability; highest perceived value.
Disadvantages: None

Die Cast

                                             

This is the most economical process for producing larger items including medals, letter openers, coasters and statuettes. Metal alloy (typically Zink alloy) is injected into a mold (die) under high pressure of 10-210Mpa (1,450-30,500) psi . The resulting surface finish, although with slightly less detail than can be seen with die struck items, has a good dimensional accuracy, as good as 0.2 % of casting dimension.

Standard Thickness: there is no standard this material and process is very flexible
Advantages: Excellent quality look; lowest price for high quantities.
Disadvantages: softer and easier to destroy although it will still take a hammer and a vice to do so!

Die Cast Enamel

This is very similar to Cloisonne, but a lot cheaper. Metal alloy (typically Zink alloy) is injected into a mold (die) under high pressure of 10-210Mpa (1,450-30,500) psi. When the metal cools we are left with a perfectly formed item. This process creates raised and recessed areas. The recessed areas are filled with enamel in the colors of your choice. The enamel is filled to the top level of the pin maintaining the traditional Cloisonnelook. Finally, all is polished to a mirror like finish and your pin is then plated in Gold, Silver, Bronze, Nickel, Black Nickel, or a Black Di finish. An optional epoxy varnish can be added to further protect your pin.

Standard Thickness: there is no standard this material and process is very flexible
Advantages: Excellent quality high value look of Cloisonnebut much lower prices.
Disadvantages: colors are not as deep or bright as Cloisonne

Chemical Etching

Standard Thickness: 0.8mm
Advantages: Works best for detailed designs; Great quality for a good price; Epoxy varnish included at no charge; Best price for low quantities.
Disadvantages: Thinner than Die Struck; epoxy lacquer must be used to protect the enamel.

Printing

For complex artwork or photo reproductions a printed pin is the way to go. We can print your pin by silk screen process for solid colors or by offset printed process when you have numerous colors, color blends, or half tones. We start by selecting a base metal in Aluminum, Brass, or Stainless Steel. We than print your image 1 color at a time directly to the base metal. Depending on the base metal chosen your pin can be plated in Gold, Silver, Nickel, or Black Nickel. Finally your pin is coated with an epoxy varnish to protect the finish.

Standard Thickness: .8mm
Advantages: Unlimited colors or detail; great for photo reproduction; no metal separating colors.
Disadvantages: Higher cost for low quantities; lower perceived value.

Pins General Information

All pins come standard with a military clutch back and are individually poly bagged. Thickness in .2mm increments can be added to most processes for an additional cost.

Electroplate Finishing

Below are examples of items in various finishes. You may use them as a basis of comparison when choosing the right finish for your custom emblem or medal.