CHALLENGE COINS
FLIGHT SUIT NAME TAGS
MILITARY PATCHES
FLIGHT SUIT NAME TAGS
MILITARY PATCHES
Die Casted vs. Die Stuck Military Coins
Service (Combat) Disabled Veteran Owned Small Business (SDVOB)
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Below is a brief overview of the processes used to produce military challenge coins and the differences. So you can pick the best process for your challenge coin design. (If price is your concern please choose the cheaper die struck method. If you want a high quality coin which you can be proud of then choose the die casted process).
Basically, there are 2 primary processes used to manufacture military coins and challenge coins. They are the Die Struck (stamped/minded) and the Die Casted (hot molded) processes.
Both of these processes produce 2D and 3D (raised) military challenge coins. The raised (2D/3D) portion of the coin is two or more flat plains on top of each other called graduation levels. These graduation levels consist of level 1 (1D), level 2 (2D), level 3 (3D). The level 2 (2D) and level 3 (3D) variations in graduation levels make the image and logo stand out and more realistic on the challenge coin.
Die Casted Process.
The die casted is a high end precision process which is used for intricate designs, where detailed precision, high detail and smooth surface quality with 2D and 3D accuracy (realism) is required.
This process is well suited for military coins and challenge coins, which have intricate designs, high detail and a requirement for fine smooth surface quality and 2D, 3D accuracy (realism).
The process consists of making a military coin design die mold then, forcing molten metal into the mold. Once the metal is cooled, the coins are removed, polished, cleaned and then paints are injected into the design on the coins
Die cast coins have unvarying, progressive 2D/3D molded into the metal which produces superior, high quality challenge coins. The die casted coins are all standard level 2 (2D), having a smooth graduation of 2D and 3D. Unlike the die struck "step-like" look of (2D/3D) multi-level die struck metal pieces "glued" together or multi-stamped.
The only limitation to the die casted method, is the edges of the wording on the coin is "rounded". On the die struck process the wording is "sharp" squared edged due to the stamping process.
Below is an example of the difference between a die casted and die struck coins.
Basically, there are 2 primary processes used to manufacture military coins and challenge coins. They are the Die Struck (stamped/minded) and the Die Casted (hot molded) processes.
Both of these processes produce 2D and 3D (raised) military challenge coins. The raised (2D/3D) portion of the coin is two or more flat plains on top of each other called graduation levels. These graduation levels consist of level 1 (1D), level 2 (2D), level 3 (3D). The level 2 (2D) and level 3 (3D) variations in graduation levels make the image and logo stand out and more realistic on the challenge coin.
Die Casted Process.
The die casted is a high end precision process which is used for intricate designs, where detailed precision, high detail and smooth surface quality with 2D and 3D accuracy (realism) is required.
This process is well suited for military coins and challenge coins, which have intricate designs, high detail and a requirement for fine smooth surface quality and 2D, 3D accuracy (realism).
The process consists of making a military coin design die mold then, forcing molten metal into the mold. Once the metal is cooled, the coins are removed, polished, cleaned and then paints are injected into the design on the coins
Die cast coins have unvarying, progressive 2D/3D molded into the metal which produces superior, high quality challenge coins. The die casted coins are all standard level 2 (2D), having a smooth graduation of 2D and 3D. Unlike the die struck "step-like" look of (2D/3D) multi-level die struck metal pieces "glued" together or multi-stamped.
The only limitation to the die casted method, is the edges of the wording on the coin is "rounded". On the die struck process the wording is "sharp" squared edged due to the stamping process.
Below is an example of the difference between a die casted and die struck coins.
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Die Struck Stamped (minted/stamped)
The die struck (stamp) method creates coins in levels, level 1, 2, 3.
Initially, dies are made for both sides of the design. Once this is done, metal is inserted between the dies and the coin design is "double stamped" simultaneously onto both sides of the metal, with about 15 tons of pressure.
The stamping process “presses” and “pushes the metal out and up to create the raised and recessed areas of the challenge coin design, which produces only produces level 1 (1D) detail.
Those coin designs which require level 2 (2D) or level 3 (3D) detail, separate cutouts are made and then "glued" on top of the recessed level 1 (1D) for the level 2 (2D). For level 3 (3D) detail a separate cutout is made and "glued" on top of level 2 (2D).
This "multi-level" 2D/3D detail gives the die struck military coins a "step like" look which has a high failure rate, where the "glued" cutouts have a tendency to separate (fall apart) and wear out.
The die struck cold stamping process can produce anywhere from 100 to 400 coins per minute. This process requires constant calibration due to the die slipping and creating off center stamping of the design.
Recommendations
The die struck manufacturing process should be the used for simple designs which require 1D detail, medals, one sided coin designs, lapel pins, tokens and badges.
The die casted process should be used for detailed complex precision designs, which require fine surface quality and level 2 (2D) and level 3 (3D), accuracy which should be a requirement for military challenge coins.
The choice is whether You want the challenge coin design "stamped" or "hot molded."
The die struck (stamp) method creates coins in levels, level 1, 2, 3.
Initially, dies are made for both sides of the design. Once this is done, metal is inserted between the dies and the coin design is "double stamped" simultaneously onto both sides of the metal, with about 15 tons of pressure.
The stamping process “presses” and “pushes the metal out and up to create the raised and recessed areas of the challenge coin design, which produces only produces level 1 (1D) detail.
Those coin designs which require level 2 (2D) or level 3 (3D) detail, separate cutouts are made and then "glued" on top of the recessed level 1 (1D) for the level 2 (2D). For level 3 (3D) detail a separate cutout is made and "glued" on top of level 2 (2D).
This "multi-level" 2D/3D detail gives the die struck military coins a "step like" look which has a high failure rate, where the "glued" cutouts have a tendency to separate (fall apart) and wear out.
The die struck cold stamping process can produce anywhere from 100 to 400 coins per minute. This process requires constant calibration due to the die slipping and creating off center stamping of the design.
Recommendations
The die struck manufacturing process should be the used for simple designs which require 1D detail, medals, one sided coin designs, lapel pins, tokens and badges.
The die casted process should be used for detailed complex precision designs, which require fine surface quality and level 2 (2D) and level 3 (3D), accuracy which should be a requirement for military challenge coins.
The choice is whether You want the challenge coin design "stamped" or "hot molded."
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Die Struck 2D/3D