Custom Enamel Pin Cut-Outs Guide: Internal Holes, Open Areas & Complex Shapes

Custom enamel pins do not have to be solid metal shapes. A design can include open areas, internal holes and custom outer contours that turn negative space into part of the artwork.

An enamel pin cut-out is a physical open area where metal is intentionally removed from the design, allowing the background behind the pin to remain visible. Cut-outs can create letters, symbols, geometric openings and complex silhouettes that would be difficult to achieve with a standard solid pin shape.

However, a cut-out is not simply an empty part of a digital illustration. The surrounding metal must still have enough physical structure to support the finished pin.

This guide explains internal cut-outs, through-holes, negative space, metal bridges, structural integrity, transparent enamel and tooling feasibility so you can decide whether a cut-out is the right solution for your custom enamel pin.

What Are the Main Ways to Create Open or Transparent Areas in an Enamel Pin?

The main options are an external custom shape, an internal cut-out, multiple cut-outs, transparent enamel or a printed visual effect. A true cut-out creates a physical opening through the pin, while transparent enamel remains a physical material inside the design.

What Is a Cut-Out Enamel Pin?

A cut-out enamel pin contains one or more intentionally open areas within or around the metal design.

Instead of producing the artwork as one completely solid metal body, selected areas are left open.

The background behind the pin becomes visible through the opening.

Cut-outs can be used to create:

• Letters
• Numbers
• Stars
• Hearts
• Geometric patterns
• Logo openings
• Character silhouettes
• Decorative negative space

Can Enamel Pins Have Holes in Them?

Yes. Custom enamel pins can include internal holes or open areas when the surrounding metal structure and tooling allow the design to be manufactured reliably.

These openings may also be described as:

• Internal cut-outs
• Through-holes
• Open areas
• Die-cut openings
• Negative-space openings

The important point is that the hole is a physical part of the product structure rather than a printed illusion.

What Is an Internal Cut-Out?

An internal cut-out is an enclosed opening located inside the outer contour of the pin.

For example, imagine a circular pin containing a star-shaped opening in the center.

The outside of the pin remains connected while the center contains a true open area.

What Is a Through-Hole?

A through-hole is an opening that passes completely through the metal body of the pin.

If you look through the opening, you can see the background behind the pin.

This is different from:

• A recessed metal area
• A black enamel area
• A transparent enamel area
• A printed shadow

Those options still contain physical material.

What Is Negative Space in Enamel Pin Design?

Negative space is the intentionally empty area around or inside the main visual elements of a design.

In graphic design, negative space can simply be the background.

In a metal pin, negative space can sometimes become an actual physical opening.

This can create a lighter and more dimensional appearance than filling every area with metal or enamel.

Internal Cut-Out vs External Custom Shape: What's the Difference?

An external custom shape changes the outside contour of the pin, while an internal cut-out creates an opening inside that contour.

Cut-Out vs Transparent Enamel: What's the Difference?

A cut-out is physically empty, while transparent enamel remains a physical material inside the pin.

This distinction is important because the two effects can look similar in digital artwork but behave very differently as manufactured products.

What Is a Metal Bridge?

A metal bridge is a narrow section of metal that connects larger parts of the pin around a cut-out or open area.

Metal bridges are important because they help keep the design physically connected.

For example:

If the connecting section becomes too narrow, the design may require adjustment.

What Is Minimum Bridge Width?

Minimum bridge width refers to the practical minimum width required for a connecting metal section to remain manufacturable and structurally appropriate for the design.

There is no single universal bridge-width value that should be applied blindly to every pin.

Feasibility depends on:

• Finished pin size
• Base metal
• Manufacturing method
• Length of the bridge
• Shape of the surrounding openings
• Pin thickness
• Nearby enamel areas
• Overall geometry

For this reason, narrow bridges should be evaluated during the manufacturability review.

How Small Can an Internal Cut-Out Be?

The smallest practical internal cut-out depends on its geometry, surrounding metal, finished pin size and manufacturing method.

A tiny circular opening and a long narrow opening may behave differently even if their overall area is similar.

The manufacturer should evaluate:

• Opening width
• Opening length
• Corner geometry
• Nearby metal bridges
• Finished product size
• Tooling accessibility

For more information about minimum features and production limits, see our Enamel Pin Design Limits Guide.

Can a Pin Have Multiple Cut-Outs?

Yes. A custom pin can contain multiple cut-outs when the remaining metal structure provides enough support for the overall design.

Multiple openings can work well for:

• Geometric patterns
• Letters
• Architectural designs
• Decorative borders
• Symbols
• Complex logos

However, every additional opening changes the internal geometry.

This does not mean multiple cut-outs are automatically problematic. It simply means the entire design should be reviewed as one physical structure.

Do Cut-Outs Make an Enamel Pin Weaker?

Cut-outs remove material, so poorly positioned or excessively large openings can reduce structural support in some designs.

The actual effect depends on:

• Location of the opening
• Amount of surrounding metal
• Number of openings
• Metal bridge width
• Finished size
• Pin thickness
• Overall shape

A well-designed cut-out pin can still be structurally appropriate for normal use.

The key is maintaining sufficient metal around critical areas rather than simply avoiding cut-outs altogether.

What Is Structural Integrity in a Cut-Out Pin?

Structural integrity describes whether the remaining metal structure can maintain the intended shape and function of the finished product.

In a cut-out design, structural integrity depends on how all of the following work together:

• Outer contour
• Internal openings
• Metal bridges
• Pin thickness
• Base metal
• Post placement
• Overall dimensions

What Is an Unsupported Metal Area?

An unsupported metal area is a section of the design that extends away from stronger surrounding geometry with limited physical connection or support.

This can occur when:

• A large cut-out surrounds a narrow metal feature
• A long decorative element is connected by a thin bridge
• Multiple openings leave isolated-looking metal sections
• A complex outer contour creates narrow projections

These areas deserve additional attention during production artwork preparation.

Can Hard Enamel Pins Have Cut-Outs?

Yes. Hard enamel designs can incorporate cut-outs when the metal structure and manufacturing process support the intended geometry.

The enamel-filled areas can retain the smooth polished appearance associated with hard enamel while selected parts of the design remain open.

This can create a strong contrast between:

For a broader comparison of enamel styles, see our Hard Enamel vs Soft Enamel Pins Guide.

Can Soft Enamel Pins Have Cut-Outs?

Yes. Soft enamel pins can also incorporate open areas when the design is compatible with the selected manufacturing process.

Soft enamel can create a particularly dimensional appearance because the design may combine:

• Raised metal
• Recessed enamel
• Open cut-out areas

This gives designers three distinct physical levels to work with.

Can Cut-Outs Be Combined With Screen Printing?

Yes. A cut-out can provide the structural negative space while screen printing adds selected fine surface details elsewhere on the pin.

For example:

These processes solve different design problems and can therefore complement each other.

Can Cut-Outs Be Combined With UV Printing?

Yes. A cut-out can create a physical opening while UV printing adds complex surface graphics, gradients or detailed illustrations to other areas of the design.

A hybrid design might use:

For a full comparison of printing methods, see our Screen Printing vs UV Printing on Enamel Pins Guide.

Can Glitter or Glow Enamel Be Used With Cut-Outs?

Special enamel effects can potentially be combined with cut-out designs when the overall specification is production-compatible.

For example, a design could combine:

• An open star-shaped cut-out
• Glitter enamel around the opening
• Glow-in-the-dark enamel in selected areas
• Standard enamel in the main artwork

However, adding more processes increases the number of production variables, so every effect should have a clear visual purpose.

What Is the Difference Between a Cut-Out and a Recessed Area?

A cut-out removes the material completely, while a recessed area remains part of the metal product but sits lower than surrounding raised areas.

What Is the Difference Between a Cut-Out and Black Enamel?

A black enamel area is still physically filled, while a cut-out is completely open.

This matters especially in digital proofs because a black area can sometimes visually resemble an opening against a dark background.

Production artwork should therefore clearly label:

If you want a true hole, the production specification should identify the area as an open area, cut-out or through-hole.

When Should You Use a Cut-Out Instead of Transparent Enamel?

Choose a cut-out when true open negative space is an important part of the design; choose transparent enamel when you want a filled area with a translucent or colored-window effect.

A cut-out works especially well when:

• The background should be completely visible
• The opening defines the logo or symbol
• You want a lighter visual structure
• The negative space is part of the silhouette

Transparent enamel may be more appropriate when:

• You want a glass-like appearance
• You want a colored transparent region
• The area should remain physically filled
• The transparent effect is part of the artwork rather than an actual hole

Do Cut-Outs Increase Enamel Pin Cost?

Cut-outs can affect the quotation when they increase tooling complexity or require a more complex manufacturing method, but there is no universal cut-out surcharge that applies to every design.

Pricing can depend on:

• Finished size
• Quantity
• Number of cut-outs
• Internal geometry
• Base metal
• Manufacturing process
• Plating
• Enamel colors
• Printing or special effects
• Tooling complexity

For accurate pricing, the artwork should be reviewed rather than estimating the cut-out as an isolated feature.

See our Custom Pin Pricing Guide for broader pricing information.

Do Cut-Outs Increase Mold or Tooling Complexity?

They can. Internal openings may require additional tooling considerations depending on the number, size and geometry of the cut-outs.

A simple central opening is different from a design containing many small irregular openings connected by narrow metal bridges.

However, the actual effect on tooling should be evaluated from the artwork rather than assumed from the number of openings alone.

What Is Tooling Feasibility?

Tooling feasibility determines whether the intended geometry can be formed reliably using the selected production method and tooling structure.

A tooling review may consider:

• Internal opening geometry
• Corner shapes
• Narrow metal bridges
• Small holes
• Outer contour
• Metal thickness
• Base material
• Production method

When Might Die Casting Be Used for Complex Open Shapes?

Die casting may be considered for some complex three-dimensional or irregular metal designs where the required geometry is better suited to a casting process than a conventional die-struck construction.

The correct process depends on:

• Product geometry
• Relief depth
• Number of openings
• Three-dimensional features
• Base material
• Finished size

A complex-looking design does not automatically require die casting. The manufacturer should select the production method after reviewing the actual artwork.

What Is Die-Struck Construction?

Die-struck construction forms the metal design using tooling that creates raised and recessed areas in the product.

It is widely associated with traditional enamel pin manufacturing because the metal structure can define:

• Outer shape
• Metal borders
• Recessed enamel areas
• Raised details

Whether an internal opening is appropriate within that structure depends on the complete production design.

Can Cut-Outs Be Used in Logo Pins?

Yes. Cut-outs can be particularly effective when negative space is already an important part of a logo.

Examples include:

• Letters with open centers
• Geometric brand marks
• Interlocking symbols
• Outline-style logos
• Emblems with internal openings

However, a logo designed for a large digital screen may contain narrow negative-space features that need adjustment when reduced to pin size.

Can Cut-Outs Be Used in Character Pins?

Yes. Character pins can use cut-outs to separate limbs, accessories, clothing details or background elements when the openings support the composition.

For example:

• Space between an arm and the body
• Open area inside a character pose
• Gap between a character and an accessory
• Decorative openings around a silhouette

The important consideration is whether the remaining metal sections stay physically connected and visually intentional.

Can Cut-Outs Make a Pin Feel More Premium?

Cut-outs can create a more dimensional and custom appearance when negative space is used intentionally, but they do not automatically make a pin higher quality.

A premium result depends on the complete design:

• Artwork quality
• Metal finish
• Enamel execution
• Cut-out geometry
• Polishing
• Printing where used
• Overall proportions

A simple design with one purposeful cut-out can often look stronger than a design with many openings added only for complexity.

How Should a Cut-Out Be Marked on Production Artwork?

Every open area should be clearly identified on the production artwork so it cannot be confused with enamel, printing or recessed metal.

A production specification should clearly distinguish:

• Metal areas
• Enamel areas
• Printed areas
• Recessed areas
• Internal cut-outs
• Outer contour

Clear production artwork reduces ambiguity before tooling begins.

What Should You Check on a Cut-Out Pin Digital Proof?

Before approval, check the position and shape of every cut-out together with the surrounding metal structure.

Review:

• Finished size
• Outer contour
• Internal cut-out shape
• Number of openings
• Metal bridge widths
• Small internal details
• Enamel fill areas
• Plating
• Printed details
• Post placement
• Backing configuration

PixelToPin provides free artwork support and a digital artwork proof within 2 hours of inquiry so the production structure can be reviewed before manufacturing.

See our Artwork Guide for more information about preparing custom pin artwork.

Where Should the Pin Posts Go on a Cut-Out Design?

Posts should be positioned on solid metal areas with enough surrounding material to support the attachment and keep the pin stable when worn.

A large cut-out can reduce the number of suitable post locations.

The production artwork should therefore consider:

• Center of gravity
• Available solid metal area
• Pin size
• Number of posts
• Rotation resistance
• Cut-out position

For larger or irregular designs, two posts may sometimes provide better orientation and stability than one, depending on the specification.

Do Cut-Out Pins Need Two Posts?

Not always. The number of posts depends on the finished size, weight, shape, balance and intended wearing position of the pin.

A small balanced cut-out pin may work with one post, while a larger or asymmetrical design may benefit from two.

The cut-out itself is only one factor in that decision.

Should You Use a Physical Sample for a Complex Cut-Out Pin?

A physical sample can be useful when the cut-out geometry, balance, structural feel or multiple production processes are especially important to the project.

Sampling may be worth considering when:

• The order quantity is large
• The design contains multiple cut-outs
• Narrow metal bridges are visually important
• The pin is large or unusually shaped
• The project requires formal approval
• The product combines cut-outs with printing or special effects

A digital proof confirms the intended design structure, while a physical sample allows the manufactured geometry and overall feel to be evaluated.

What Should You Send a Manufacturer for a Cut-Out Pin Quote?

Send the original artwork together with the intended finished size, quantity and a clear indication of which areas should be physically open.

The most useful information includes:

• Artwork file
• Finished dimensions
• Quantity
• Hard or soft enamel preference if known
• Plating preference
• Cut-out areas
• Printing requirements
• Backing preference
• Packaging requirements
• Required delivery date

If you are unsure whether an area should be a cut-out or transparent enamel, you can send the original artwork and explain the visual result you want.

Custom Enamel Pin Cut-Out Design Checklist

Before approving a cut-out enamel pin, confirm that the negative space works both visually and structurally at the final physical size.

• Is the finished pin size confirmed?
• Which areas are true physical cut-outs?
• Could any area be confused with black enamel?
• Should any area use transparent enamel instead?
• Are internal openings large enough to manufacture reliably?
• Are narrow metal bridges structurally appropriate?
• Are multiple cut-outs necessary?
• Does the outer contour remain strong and clear?
• Are unsupported metal areas minimized?
• Is post placement on a solid metal area?
• Does the pin need one post or two?
• Are screen-printed or UV-printed areas clearly identified?
• Has tooling feasibility been reviewed?
• Has the artwork received a manufacturability review?
• Is a physical sample useful before mass production?

Frequently Asked Questions

Can enamel pins have holes in them?

Yes. Custom enamel pins can include internal cut-outs or through-holes when the surrounding metal structure and selected manufacturing process support the design.

What is a cut-out enamel pin?

A cut-out enamel pin contains an intentionally open area where metal has been removed from the design. The background behind the pin can be seen directly through the opening.

What is an internal cut-out?

An internal cut-out is a physical opening located inside the outer perimeter of the pin.

What is the difference between a cut-out and transparent enamel?

A cut-out is physically empty, while transparent enamel remains a physical material inside the design. Use a cut-out for true open space and transparent enamel for a translucent or colored-window effect.

What is a metal bridge?

A metal bridge is a narrow metal section connecting larger parts of the pin around an opening or cut-out.

How small can a cut-out be?

The minimum practical cut-out size depends on its geometry, surrounding metal, finished pin size and manufacturing process. The artwork should be reviewed before tooling rather than relying on one universal minimum measurement.

Can a pin have multiple cut-outs?

Yes. Multiple cut-outs are possible when the remaining metal structure provides sufficient support and the tooling can reproduce the intended geometry.

Do cut-outs make enamel pins weaker?

Cut-outs remove material, so their size and placement can affect structural support. A well-designed cut-out pin can still be suitable for normal use when sufficient metal remains around critical areas.

Can hard enamel pins have cut-outs?

Yes. Hard enamel pins can incorporate cut-outs when the metal structure and manufacturing process are compatible with the intended geometry.

Can soft enamel pins have cut-outs?

Yes. Soft enamel designs can combine raised metal, recessed enamel and true open areas when the design is production-compatible.

Can cut-outs be combined with UV printing?

Yes. A cut-out can create physical negative space while UV printing adds complex graphics, gradients or fine details to other areas of the pin.

Do cut-outs increase enamel pin cost?

They can affect the quotation when they increase tooling or manufacturing complexity. Final cost depends on the complete specification, including size, quantity, number of openings, material and additional processes.

What is negative space in enamel pin design?

Negative space is intentionally empty space around or inside the main design elements. In a cut-out pin, that negative space can become an actual physical opening.

Do cut-out pins need two posts?

Not necessarily. Post quantity depends on the pin's size, weight, balance, shape and available solid metal area rather than the presence of a cut-out alone.