01
Central ReliefDepth is the first decision, not the last.
The primary emblem is raised noticeably higher than the surrounding field, so the center reads as the visual anchor from any angle and catches light on its own.
Custom Coin Case Study
A double-sided coin built to be held.
A custom challenge coin is easy to make. Making one that feels substantial in the hand is not. This project treats the front, reverse and edge as one physical object, with 3D relief driving every design decision.
45 mmCoin Diameter
3.5 mmCoin Thickness
2 SidesFront + Reverse
360°Edge / Object View
Hero ObjectFront / Back / Edge
01 · The Brief
The client did not want another thin metal tag.
The project came from a recognition program that had already tried a stock challenge coin. The previous piece carried the right artwork, but it felt light and flat in the hand — closer to a printed token than a keepsake. The brief for this project was specific: it had to feel different the moment someone picked it up.
Core Requirements
- Deliver a coin that feels substantial in the hand, not a thin metal tag.
- Make the 3D relief visible in photographs without additional lighting.
- Keep both sides readable on their own, without one feeling like filler.
- Ensure the edge and thickness match the visual weight of the front face.
02 · The Design
3D relief became the project's central decision.
Once the coin needed to feel substantial, every other design choice followed. The relief depth determined where the eye lands, how the metal catches light, and how the coin reads in the hand. The design was planned around that constraint from the first sketch.
02
Edge TreatmentThe perimeter has to match the face.
A thicker edge and a textured rim reinforce the sense of mass. The coin is designed to be picked up, not just looked at from the front.
03
Finish & ContrastContrast makes the relief readable.
Antique recesses and polished raised areas separate the layers without adding visual noise. Depth becomes readable in photographs and in hand.
03 · The Build
Specifications, then proof the relief survived production.
Relief planning matters only if it holds up once the coin moves from screen to metal. The specification below set the target. The production flow below that showed how the target stayed on track.
- Material
- Zinc Alloy / Custom Metal
- Diameter
- 45 mm
- Thickness
- 3.5 mm
- Finish
- Antique + Polished Contrast
- Front
- 3D Relief + Raised Emblem
- Back
- 3D Relief + Fine Detail
- Edge
- Textured / Machined Edge
- Packaging
- Individual OPP + Presentation Box
Production Flow
From artwork to a physical object with real depth.
01
Artwork Review
Confirm the visual hierarchy, intended meaning and manufacturing constraints before modeling.
02
3D Development
Separate the artwork into relief layers, recessed areas, text and edge details.
03
Sample Approval
Review front / back details, metal appearance, plating contrast and edge treatment.
04
Production
Tooling, forming, plating, polishing, coloring, finishing and quality inspection.
05
Presentation
Pack the finished coins for delivery so the object arrives as a complete recognition piece.
Unplated Blank · Relief Check
The relief was checked before any plating was applied.
Before the coin entered the plating stage, the unplated blank was inspected for relief height, edge thickness and surface consistency. If the depth was not correct at this stage, it could not be fixed later. The blank confirmed the 3D relief held up in real metal.
04 · The Outcome
Front, reverse and edge should feel like one object.
The finished coin is shown below as a real object — front face, reverse face and physical presence included. The result is a recognition piece that reads as a keepsake, not a giveaway.
Front face · Hero side01 / FRONT
01 / FRONT
Lead with the identity.
The front side establishes the primary symbol, hierarchy and visual weight of the coin. Relief depth keeps the central mark readable while giving the metal a strong light-and-shadow response.
Design PrincipleEvery side should still feel complete when seen alone.
Project Outcome
A recognition piece that feels more like an object than a giveaway.
The value of a challenge coin comes from its physical presence. By treating both sides and the edge as part of a single visual system, and by committing to 3D relief as the first decision, the finished piece feels more considered and easier to keep.
2 SidesDesigned as one visual system
3.5 mmSubstantial metal presence
360°Front / back / edge considered
DemoRepresentative project data
"The goal was never to make both sides busy. It was to make both sides feel intentional — so the coin still looked complete no matter which face the owner happened to hold."
— Product Development Lead