Custom Commemorative & Challenge Coins Factory

Custom 3D Commemorative & Challenge Coins: Factory Direct

Custom 3D Commemorative & Challenge Coins: Factory Direct

Description :

Engineering Highlights:

Dual-Material Minting Precision: High-pressure stamped Solid H65 Brass for mirror fields and authentic numismatic acoustic ring; or Zamak 3 Zinc Alloy for ultra-deep 3D sculptural reliefs up to 2.0mm.
CNC Precision Edge Machining: 8 distinct edge treatments including classic Reeded Edge, Diamond Cut (Spur, Cross, Wave, Bevel), and sequential laser-engraved serial numbers (001/500).
Museum-Grade Protective Packaging: Each coin comes individually housed in a scratch-resistant airtight acrylic capsule with custom foam gaskets, preserving pristine mirror luster against oxidation.

Quick Specs Overview:

• Standard Diameters: 1.50″ (38mm) | 1.75″ (44mm) | 2.00″ (50mm) | 2.50″ (65mm) | Custom up to 3.50″ (89mm)
• Coin Thickness Range: 3.0 mm ~ 5.0 mm (Ensures substantial hand weight and rigid structural heft)
• Plating & Finishes: 24K Polished Gold, Antique Bronze/Silver/Copper, Matte Sandblast, or Dual-Tone Electroplating
• Color Embellishment: Hard Enamel (Cloisonné-flush polish), Soft Enamel, Transparent over knurled guilloché, Silk-screen/UV prints
• Tooling Guarantee: Pay mold fee once; steel dies are preserved in climate-controlled die vaults for 3 years with zero mold fee on reorders.

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Product Description:

Technical Specifications & Engineering Tolerances

Technical Parameter	Gold Valley Factory Specification & Tolerance
Base Material Options	High-density Zamak 3/5 Zinc Alloy (Die-casting) or Solid H65 Brass (Hydraulic Minting Press)
Standard Diameters	1.5″ (38.1mm), 1.75″ (44.5mm), 2.0″ (50.8mm), 2.25″ (57mm), 2.5″ (63.5mm), up to 3.5″ (88.9mm) (±0.1mm)
Coin Thickness Baseline	3.0mm, 3.5mm, 4.0mm, 4.5mm, 5.0mm (Substantial hand weight, zero warping)
3D Relief Depth	Up to 2.0mm high-sculptural relief (Zinc die-cast); sharp micro-relief down to 0.8mm (Brass minting)
Edge Machining Options	Reeded Edge, Smooth Flat Edge, Diamond Cut (Spur / Cross / Wave / Bevel / Rope), Laser Edge Numbering
Plating & Surface Treatments	Shiny Gold/Silver/Nickel/Copper, Antique Bronze/Silver/Brass, Two-Tone Dual Plating, Sandblasted Matte Fields
Protective Sealing & Corrosion	Electrophoretic clear nano-lacquer passed 48-Hour Neutral Salt Spray (NSS) anti-tarnish test (ASTM B117)
Protective Packaging	Airtight Optical Acrylic Capsule (Standard); Deluxe Velvet Box, Leatherette Display Case, Acrylic Stands (Optional)
Production Lead Times	Digital 3D Vector Proof: 2-4 Hours \| Physical Samples: 5-7 Days \| Mass Minting: 12-18 Days (Rush available)
Compliance Certifications	Disney FAMA (FAC-086164), NBCUniversal (L-8360-DT-004), Sedex SMETA 4-Pillar, ISO 9001:2015, RoHS/EN71

Material & Minting Selection: Solid Brass vs. Die-Cast Zinc Alloy

• Hydraulic Stamped Solid Brass (H65)

Best for: Official military challenge coins, commemorative currency replicas, high-end VIP numismatics, and mirror-proof cameo finishes.

Acoustic Resonance: Produces a crisp, distinctive high-pitch metallic ring when flipped or tapped.
Mirror-Like Proof Field: Flat areas achieve an authentic mirror polish with frosted relief contrast (Cameo effect).
Razor-Sharp Edging: Crisp die-strike perimeter ideal for reeded fluting and micro-lettering.
Prestigious Density: Heavy metal feel (8.5 g/cm³) delivering genuine heft in the palm.

• High-Pressure Die-Cast Zinc Alloy (Zamak 3)

Best for: Multi-tiered sculptural architectural motifs, detailed portrait busts, cutout designs, and budget-optimized volume programs.

Deep 3D Sculptural Depth: Capable of up to 2.0mm bas-relief depth with steep undercut angles impossible in stamping.
Cutouts & Functional Components: Accommodates hollow centers, integrated bottle openers, and spinning coin assemblies.
Tooling Economy: Cost-effective steel tooling for large diameters (>2.5 inches / 65mm).
Dimensional Integrity: High fluid-fill precision ensures zero shrinkage on delicate facial contours.

8 Distinct CNC Precision Edge Milling Treatments

Elevate your challenge coin from a basic flat disc into a tactile collectible. Gold Valley operates dedicated high-speed CNC edge-milling lathes providing 8 standard and custom patterns:

1. Standard Reeded EdgeClassic sovereign currency fluting. Provides anti-counterfeit aesthetics and slip-free grip.	2. Smooth Flat EdgeMirror-buffed perimeter showcasing the coin’s full thickness and clean profile.	3. Diamond Cut / SpurAngled faceted cuts that refract light like gemstones when tilted under direct light.	4. Cross Cut / KnurledCriss-cross diamond grid pattern offering a rugged, tactical military handle.
5. Rope / Beaded EdgeTraditional maritime twisted cable border, favored by naval and law enforcement units.	6. Wave / Curve CutScalloped undulating edge cuts creating fluid, wave-like perimeter reflections.	7. Petal / Swirl CutRadiating sunburst swirls milled around the coin rim for maximum visual dynamics.	8. Laser Edge NumberingSequential numbering (e.g., 001/500) or motto laser-etched along the outer rim edge.

Electroplating Matrix & Master Two-Tone (Dual Plating) Technology

[Craft] Two-Tone (Dual-Tone) Plating

Combines two distinct electroplated finishes on a single coin—such as Polished 24K Gold highlights over Matte Antique Silver recesses. Executed via high-temperature masking or CNC laser peeling.

[Testing] 48-Hour NSS Salt Spray Anti-Tarnish Sealing

All antique and polished metal finishes receive a baked-on transparent nano-electrophoretic lacquer. Tested under ASTM B117 48-Hour neutral salt spray to ensure zero tarnishing from finger acidity and humidity.

Airtight Capsule & Archival Presentation Packaging

Optical Acrylic CapsuleStandard inclusion. Snap-tight crystal-clear capsule with custom EVA foam spacer ring for zero rattling.

Deluxe Velvet BoxSteel jewelry box wrapped in royal navy, burgundy, or black velvet with gold-foil stamped inner lid liner.

Leatherette Magnetic CaseFoldable easel-back magnetic leatherette case for executive desk exhibition and VIP gifting.

Retail Blister PackFull-color printed 350g cardstock sealed inside clear thermoformed blister for souvenir store racks.

Dongguan Direct-Factory Manufacturing SOP & Quality Assurance

Step 1: CAD 3D Sculpting & CNC Die Carving

Engineered using imported hardened die steel on high-speed CNC engraving machines down to 0.02mm tolerance.

Step 2: 500-Ton Hydraulic Minting / Die-Casting

Dual 500-ton hydraulic coin press strikes solid brass blanks up to 3 times to produce razor-sharp bas-relief details.

Step 3: CNC Edge Milling & Faceting

Specialized edge-turning lathes carve reeded, cross, or diamond facets onto each coin perimeter.

Step 4: Automated Electroplating & Anti-Tarnish Sealing

Multi-stage ultrasonic degreasing, precious metal electroplating, and baked-on 48-hour NSS salt spray clear lacquer.

Step 5: Hand Enameling & Mirror Buffing

PMS Pantone color matching with needle-dispensed enamel; hard enamel is whetstone polished flush to metal lines.

Step 6: 100% Optical Inspection & Encapsulation

Cleanroom inspection under 10x magnification; each coin is immediately sealed into airtight acrylic capsules.

Frequently Asked Procurement & Engineering Questions

Q1: How do I choose between Solid Brass and Zinc Alloy for my custom coin project?

A: If your priority is authentic heavy hand heft, razor-sharp lettering, mirror-like proof backgrounds, and that distinct high-pitch ringing chime (standard for military unit challenge coins and government awards), choose Solid H65 Brass. If your design features intricate, multi-level 3D sculptural reliefs, hollow cutouts, or larger diameters (>2.5″ / 65mm), choose Zamak 3 Zinc Alloy for superior fluid mold filling and tooling value.

Q2: What is Gold Valley’s mold retention and reorder policy?

A: You pay the steel die tooling fee only once on your initial order. Your custom dies are laser-indexed, ultrasonic-cleaned, coated with anti-rust oil, and stored in our climate-controlled die library for 3 full years. Any reorders placed within 3 years incur $0.00 tooling charge.

Q3: Are the acrylic capsules included, and will the coins rattle inside?

A: Yes, individual airtight optical-grade acrylic capsules are included by default. We precisely calibrate inner capsule depth and diameter to match your exact coin dimensions (e.g., 44mm x 3.5mm), or insert a laser-cut high-density EVA gasket ring to guarantee zero rattling and full 360° edge protection.

Q4: Can you produce Two-Tone (Dual-Plated) coins and sequential serial numbers?

A: Absolutely. We regularly manufacture dual-plated coins (e.g., Antique Gold base with High-Polished Nickel raised emblem) and can laser-engrave sequential serial numbers (e.g., 001/500) directly onto the coin face or along the outer reeded edge for limited edition runs.

Q5: What artwork file formats do you require, and do you assist with 3D sculpt proofing?

A: We accept vector files in .AI, .EPS, .PDF, or .SVG. If you only have a flat .PNG, .JPG, or a rough sketch, our engineering team provides complimentary 3D vector and relief proofing within 2 to 4 hours, showing exact metal lines, PMS Pantone colors, and simulated edge cuts before tooling starts.

Q6: What factory audits and social compliance credentials does Gold Valley hold?

A: Our Dongguan manufacturing facility holds verified Disney FAMA authorization (FAC-086164), NBCUniversal compliance (L-8360-DT-004), Sedex SMETA 4-Pillar ethical audit, and ISO 9001:2015 quality certification. All raw materials and electroplated layers strictly comply with US CPSIA, California Proposition 65 (lead & cadmium free), and EU RoHS/REACH standards.

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