Challenge Coin Case Study

Building a Detailed Dual-Sided Commemorative Coin

See how PixelToPin transformed detailed dual-sided artwork into a premium antique bronze challenge coin with strong relief, readable curved text and presentation-ready packaging.

Dual-sided antique bronze commemorative challenge coin
The Project

Project Overview

This project required a timeless commemorative coin featuring a heraldic eagle on the front and a detailed world map on the reverse.

The goal was to preserve fine relief, curved lettering and symbolic details while creating a substantial metal piece with a consistent antique finish and a distinctive rope edge.

Close-up of antique bronze eagle relief on a challenge coin
Design Transformation

From Concept Artwork to Finished Coin

Both sides were converted into production artwork with clear relief levels and readable circular text.

Production Artwork
Front and reverse production artwork for a custom challenge coin
Finished Coin
Finished front and reverse antique bronze challenge coin
Production Goals

Client Requirements

Clear Dual-Sided Details

Keep the eagle, world map and fine symbols sharp.

Strong Antique Finish

Create deep contrast between raised and recessed metal.

Readable Curved Text

Maintain clear lettering around both coin faces.

Premium Presentation

Protect each coin with an appropriate display package.

Our Approach

Recommended Materials & Process

Each production step was selected to balance relief depth, clarity and long-term durability.

01

Artwork & Relief Planning

We defined raised, recessed and textured zones before preparing both sides for tooling.

Challenge coin artwork and relief planning
02

Die Casting & Polishing

The zinc alloy coin was cast, edge-finished and selectively polished to sharpen raised details.

Challenge coin die casting and polishing process
03

Antique Plating & Inspection

Antique bronze treatment was applied before checking relief, lettering, edge and surface consistency.

Antique bronze challenge coin quality inspection
Technical Execution

Production Challenge & Solution

The Challenge

The world map, curved lettering and narrow relief spaces required careful planning to remain clear after casting and antique finishing.

  • Small landmass details risked filling during casting
  • Curved text needed consistent spacing
  • Antique color could obscure shallow relief

Our Solution

We strengthened key relief zones, adjusted letter spacing and controlled polishing and antiquing to preserve visual depth.

  • Reinforced important map and crest details
  • Opened narrow spaces around circular text
  • Balanced dark recesses with polished highlights
Final Outcome

Finished Result

Finished commemorative coins with velvet pouch and presentation box

A Substantial, Presentation-Ready Coin

The finished coin combines deep dual-sided relief, controlled antique bronze contrast and a distinctive rope edge. Both faces remain readable while retaining the traditional weight and character expected from a commemorative coin.

The velvet pouch and optional presentation box prepare the coin for recognition programs, events, clubs and commemorative releases.

At a Glance

Product Specifications

ProductCustom Challenge Coin
MaterialZinc Alloy
Size1.75 in / 44.5 mm
Thickness3.5 mm
FinishAntique Bronze
DesignDual-Sided Relief
EdgeRope Edge
PackagingVelvet Pouch / Gift Box
Antique bronze challenge coin rope edge and raised world map detail
Helpful Information

Frequently Asked Questions

What is the minimum order quantity for custom challenge coins?

PixelToPin typically starts custom challenge coin production at 100 pieces. Contact us if your project requires a different quantity.

Can I see a proof before full production?

Yes. We provide digital production artwork for approval before tooling. Physical samples may also be available depending on the project schedule and requirements.

How long does challenge coin production take?

Production time depends on the design, finish, quantity and packaging. Typical mass production takes approximately 7–12 business days after artwork and sample approval.

What packaging options are available?

Options include clear bags, velvet pouches, plastic coin capsules and premium presentation boxes. We can recommend packaging based on the intended use.

Ready to Create Your Own?

Create a Custom Coin That Tells Your Story

Send us your artwork and receive process recommendations, production guidance and a free custom quote.

Custom Product Pricing FAQ

Clear answers about custom product pricing, mold fees, minimum quantities, shipping costs, volume discounts, artwork, and reorders.

How is custom product pricing calculated?

Pricing is based on the product type, size, thickness, quantity, number of colors, metal plating, artwork complexity, attachments, special effects, packaging, and shipping destination. Send us your artwork and requirements to receive an itemized factory-direct quotation.

Does the quoted price include mold and setup fees?

Your quotation will clearly show any mold or setup fees required for the project. Most new custom metal designs require a mold because the shape and artwork are made specifically for your order. There are no additional charges beyond the items confirmed in your quotation.

Does the price include shipping, duties, and taxes?

Shipping costs are calculated based on order weight, packaging, destination, and delivery method. Your quotation will state whether shipping is included or listed separately. Import duties, taxes, and customs fees may apply depending on the destination and agreed shipping terms.

Do larger quantities receive lower unit pricing?

Yes. The unit price generally decreases as the order quantity increases because mold, setup, and production costs are distributed across more pieces. Contact us for quantity-based pricing at 50, 100, 300, 500, or 1,000 pieces.

Can I combine different designs to reach the minimum order quantity?

Each completely different design normally requires its own mold and minimum quantity. Color variations using the same shape and mold may sometimes be combined, depending on the production process. Send us all designs for confirmation before ordering.

Are artwork revisions and reorders charged separately?

Initial artwork review and standard production-proof revisions are provided free of charge before approval. Reorders using the same approved design may have lower setup costs if the original mold remains available and suitable for production. Design, size, or mold changes will be quoted separately.