How to Produce a Challenge Coin
Challenge coins are common among military personnel. The coins prove membership in a troop or unit. Groups outside the military have begun using challenge coins to identify themselves, as the tradition has never been a government regulated activity. Any group may design, produce and use challenge coins for their organizational activities. The coins are not legal tender; they are strictly for decorative purposes.
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Instructions
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Create a design for the coin. Decide what mascot, motto, and colors to use for the coin. Coins are roughly the size of an American half dollar piece, so the mascot will be clear. The mascot and motto on the coin should be the same used for the organization.
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Design a color proof. Color proofs are the rough copy of the design to be imprinted on the brass, copper, silver or gold face of the challenge coins. Make changes to the color proof if necessary to achieve the desired design. After the color proof is approved and set in a dye, changes will be impossible.
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Cut a 2D raised metal copy of the approved design into a master die. For 3D effects, a plaster cast is required, usually with the assistance of a master craftsman. Once the plaster is set for the 3D coin, make a rubber inverted mold. Fill the rubber mold with plastic resin; allow the resin to dry. The resin will produce the 3D master die.
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Produce coins by pressing the master die, either 2D or 3D, into soft metal, then allowing the metal to cool, holding the shape of the design.
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Tips & Warnings
Creating coins of any type requires master skill with metal working. Do not attempt to create a challenge coin without expert metal working skill. For challenge coins made safely, order a color proof and send the approved design to a master coin maker.
