| Primarily there are 2 processes used to produce | | | | lettering, which is more "rounded" unlike the die |
| challenge coins. The die casted (hot molded) and the | | | | struck process which produces "squared" sharp |
| die struck (stamped/minted) process. | | | | edged lettering due to the stamping process. |
| Both of these process produce 2D/3D (raised) | | | | Die Struck (stamped/minted) Challenge Coins |
| challenge coins. The 2D/3D (raised) consists of two | | | | The die struck process produces coins in levels. First, |
| or more flat plains on top of each other called | | | | a die for both sides of the design is made. Then a |
| graduation levels. These graduation levels are level 1 | | | | metal is placed between the die's and the design is |
| (1D), level 2 (2D), level 3 (3D). The 2D/3D variations | | | | "double stamped" simultaneously on both sides with |
| or graduation in levels makes the logo or image more | | | | about 15 tons of pressure, to get the raised and |
| realistic. | | | | recessed areas of the design. This process "pushes" |
| In the case of the die casted process the 2D/3D is | | | | and "presses" the metal up and out to form the |
| molded into the coin metal. In the die struck coins the | | | | challenge coin design, level 1 (1D). |
| 2D/3D are metal cutouts "glued" together, into the | | | | The military challenge coin designs which require two |
| recessed areas of the die struck military coins. | | | | or more levels of detail (2D/3D), the die struck |
| Die Casted Challenge Coins. | | | | process consists of making metal cut-outs of the |
| The die casting manufacturing process, is a high end | | | | designs and then "glued" on top of the level 1 (1D) |
| efficient process for precision designs, producing the | | | | for the 2D logo or image. The 3D (logo or image) is |
| highest quality military challenge coins. It is especially | | | | "glued" on top of the 2D. |
| suited for applications which require high detail, | | | | This 2D/3D "multi-level" detail of a die struck military |
| complex designs and a fine surface quality and | | | | coin, gives the challenge coin a "step like" look and |
| dimensional consistency, as required in military coins. | | | | has a high failure rate; meaning the "glued" pieces fall |
| The end result of the die casted manufactured | | | | apart or wear out. |
| military coin is a uniform design, excellent surface | | | | Due to the labor intensive and the high cost of |
| finish and good dimensional (2D/3D) accuracy | | | | producing 2D and 3D challenge coins, majority of the |
| (realistic) and a superior challenge coin quality. | | | | die struck manufactures only produce level one (1D) |
| The die casted process consists of forcing molten | | | | detail using the "double stamping" method. Even |
| metal under high pressure into mold cavities (die | | | | though they state their process produces 2D and 3D |
| molds). Once the metal is cured, each coin is | | | | detail. |
| removed, cleaned, polished and then enamel paints | | | | In conclusion, the die casted manufacturing process |
| are injected into the design. | | | | should be the process of choice for producing high |
| Unlike the die struck "step-like" look of (2D/3D) | | | | quality, detailed 2D/3D challenge coins. The die struck |
| multi-level die struck metal pieces "glued" together. | | | | manufacturing process should be the process of |
| Die cast coins have smooth, gradual 2D/3D molded | | | | choice for simple designs which require level 1 (1D) |
| into the metal to produce a high quality, superior | | | | detail, one sided coin designs, leather, lapel pins, |
| military coin. All die casted coins are all standard 2D. | | | | tokens, badges and off course our coin currency. |
| The limitation of the die casted process is the | | | | |