How to Design a Custom Challenge Coin: A Step-by-Step Guide

Designing your first custom challenge coin can feel overwhelming — size, thickness, plating, enamel type, shape, and artwork all need decisions. But it doesn't have to be complicated. Here at Honest Coins LI, we've guided hundreds of police officers, firefighters, veterans, and corporate teams through the process. This guide walks you through every step.

Step 1: Choose Your Size

Challenge coins come in a range of sizes, typically from 1.5 inches to 3 inches in diameter. The most popular sizes are:

• 1.75" — Compact, classic military style, easy to carry in a pocket

• 2.0" — The most popular size. Plenty of room for detailed artwork and text.

• 2.25" — Our standard at HonestCoinsLI. Premium, substantial feel.

• 2.5"+ — Display coins, collector pieces, or coins with lots of detail

Step 2: Pick Your Thickness

Thickness runs from 1mm (thin, light, budget) to 4mm (premium, heavy, impressive). We build all our standard coins at up to 4mm thick because a coin that feels substantial is a coin that gets carried. Most companies charge extra for thicker coins — we include it in our standard pricing.

Step 3: Choose Your Shape

Round coins are classic, but cut-to-shape coins are increasingly popular — badges, state shapes, shields, stars, or any custom silhouette. Cut-to-shape coins cost a little more due to tooling but create something truly unique that stands out on display.

Step 4: Select Your Plating

Plating is the metal finish on the surface of your coin. Common options include:

• Gold — Classic, prestigious, warm tone. Great for retirement and commemorative coins.

• Silver — Clean, sharp, modern look. Popular for law enforcement and corporate coins.

• Black Nickel — Dark, bold, tactical. Very popular in military and SWAT units.

• Antique Gold/Silver — Aged, weathered look. Great for historical and traditional designs.

• Dual Plating — Two different metals on the same coin. Creates striking contrast.

Step 5: Decide on Enamel

Enamel adds color to your coin. The two main types are soft enamel (textured surface where raised metal ridges sit above the recessed color fill) and hard enamel (color is polished flush with the metal — extremely smooth and durable). Hard enamel is more expensive but produces a higher-end, jewel-like finish.

Step 6: Provide Your Artwork (Or Let Us Design It Free)

You don't need to be a graphic designer to get started. All you need is a rough idea: a photo of a patch, a badge, a logo, or even a hand sketch. We provide completely free artwork and unlimited revisions — our design team turns your concept into a production-ready digital proof within 48 hours. You approve it before anything goes into production.

Ready to start? Email info@honestcoinsli.com or visit our Free Quote page at HonestCoinsLI.com to get started with no cost and no commitment.