From Sketch to Strike: The Design Process Behind Custom Metal Emblems

Want to turn an idea into a piece of metal that lasts forever?

Take a pencil sketch on a napkin to a finished coin and it's quite an adventure. There's art. There's science. There's Frankenstein.

And here's the kicker...

Process is what makes each coin unique. Every stroke, every bend, every minute detail.

Learn every step involved in designing custom metal emblems so your journey from concept to creation is fully understood.

Time to dig in!

Inside This Guide:

• The Story Behind Custom Coin Shapes
• Step 1: Concept and Rough Sketches
• Step 2: Picking the Right Shape
• Step 3: Digital Artwork and Proofing
• Step 4: Mould Creation and Striking
• Step 5: Finishing and Final Touches

The Story Behind Custom Coin Shapes

Custom coin shapes have evolved from the antiquated circular forms.

Designers can create coins today that look like dog tags, shields, badges, weapons, cars or planes, even animals. That sort of liberty revolutionizes the design process.

Here's why this matters:

Okay, a round coin will do. But a coin molded in the likeness of your unit's mascot or some piece of gear really speaks volumes before anyone even reads the motto.

The Department of Defense claims challenge coins have been around as an American tradition for 100 years. That tradition continues to expand as new molds and designs allow units to embody something special about themselves.

That's why many companies that produce Marine Corps challenge coins take great care in the beginning stages of shape and concept. Custom coin shapes make the first impression... before anyone even reads the writing on the coin.

If you nail down the shape, everything else about the design becomes much easier.

Step 1: Concept and Rough Sketches

Every great coin starts with a pencil and a blank piece of paper.

Concepting is throwing around ideas, doodling, screwing up, starting over. Messiest part. Most important part.

A good concept phase usually includes:

• A clear purpose for the coin (award, unit, commemorative)
• Key symbols, mottos, or imagery
• Colour ideas
• Notes on size and weight

Perfect is not important at this stage. Throw out every idea you have so the designer will know everything you want.

Tip: The strongest thumbnails typically show several options on one page. This allows for greater flexibility when combining elements.

Step 2: Picking the Right Shape

Now comes the fun part... Picking from all the custom coin shapes available.

This decision arguably has the most weight of any. Shape drives the rest of the process.

The most popular custom coin shapes include:

• Classic round (still the most common)
• Shield shapes (great for crests and emblems)
• Dog tag silhouettes
• Spades or arrowheads
• Mascot or animal outlines
• Vehicle shapes (planes, ships, trucks)
• Weapon-inspired designs

Here's the thing: the shape needs to match the message.

The shield lends itself to security and law enforcement coins. Spades or arrowheads can work for combat units. Detailed engraving is perfect for a round coin issued for formal awards or anniversaries.

Choosing the proper form allows the rest of the creative process to flow effortlessly. This also allows the completed coin to have more significance to the recipient.

Step 3: Digital Artwork and Proofing

After the sketch and shape are finalized, the design is transferred to a computer.

This is where scribbles turn into a finalized digital file ready to go to production. You will see that an experienced designer will:

1. Clean up the lines
2. Adjust the proportions
3. Add or remove detail based on the chosen size
4. Map out the colour zones
5. Build the front and back of the coin separately

Then comes the proofing stage.

The proof is by far the most crucial review step in the entire process. All of the details are double and triple (and quadruple) checked before the coin even comes near a mould.

Why is proofing so important? After a mould is cut, modifications are costly. Typos are much easier to catch on screen versus on a completed die.

Take time at this stage. Review everything carefully.

Step 4: Mould Creation and Striking

This is where the magic really happens.

When artwork is approved it's transferred to a steel die. The die strikes the design onto the raw metal blank. Coin striking requires a lot of pressure.

Here's how the striking process works:

1. A blank disc of metal is placed in the press
2. The die comes down with massive force
3. The design gets pressed into the metal
4. The coin is removed and inspected

That's basically it. It hasn't evolved much over centuries, but technology has allowed for more precise and consistent details.

One military coin source, Soldiers Angels, even states that challenge coins date back to the Roman Empire. Roman soldiers were rewarded for acts of bravery with medallions. Today's striking process originated with them.

Pretty cool, right?

Step 5: Finishing and Final Touches

The coin is struck. But the design process isn't done yet.

Finishing is the final step. This is where your plain jane coin transforms into a work of art. There are many finishing choices that can drastically alter the appearance of your coin.

Common finishing options include:

• Gold, silver, or copper plating
• Antique finishes (worn, aged look)
• Hard enamel for smooth, glossy colour
• Soft enamel for textured, dimensional colour
• 3D sculpting for added depth
• Edge cuts (rope, scalloped, oblique)

Each finish gives the coin a different feel.

Mirror finished gold plate with hard enamel feels very formal and sterile. Antique silver plated looks hand crafted, vintage.

The final stage allows for the most personal preference. Two coins can have identical designs but appear completely different with various finishes applied.

The Bottom Line

Creating custom metal emblems is part art, part engineering and part tradition.

Whether it's pencil design work to final polish, each step contributes to the finished coin. Jump ahead or rush the job, you will see the difference.

A quick recap of the journey:

• Start with a clear concept and rough sketches
• Pick the right shape for the message
• Build a clean digital proof and review it carefully
• Strike the coin with the right die
• Add the finishing touches that bring the design to life

Coins last for decades. Sometimes longer.

It also means whatever choices are made in the design process are carried forward for eternity. A good coin design becomes history... A bad one becomes a door stop.

It will take time. Craft it carefully. The finished product is worth the time spent designing.