Lapel pins are made through a systematic process with a number of critical steps feeding into the quality and aesthetics of the final product. The most basic level of the design process will usually start with creating a piece of design, or an image to represent the pin. The design typically details the size of the pin (which generally falls between 0.75 inches and 1.5 inches in diameter), color information, text if desired, any particularly fine lines/details encountered within the artwork/etc.. More control over these elements is possible through modern design software, so in the final product will be on par with how you want it to look like and as per your customer requirement.
When the design is finalized, it goes to make a mold. The digital design is used to create a mold — often made of steel, as it needs to be able to withstand the high temperatures and pressures during production. This mold is the master that all resulting pins will be based off of during production. An accurate mold within 0.01 inches is needed for suitable lapel pins production, and makes all the created enamel pin on same size and elaborate degree.
The next process includes stamping or die-casting (as accordance with the lapel pin type). In very simple terms, a stamped pin is made by pressing the mold into certain type of sheet metal such as copper or brass and applying forces ( up to 50 Tons ) on it containing your design. DCIM100MEDIADJI_0665.JPGThe process involves high-pressure stamping that impacts the design into metal producing a raised and recessed image. Die-cast pins require molten metal to be injected into the mold, which allow for much more intricate 3D shapes. This process is frequently implemented when the custom lapel pins have unique or complex patterns.
That metal base is then plated. Finishing may include plating the resulting item with gold, silver, nickel or black nickel. They are then submerged in a plating solution where an electric current is used to bond the applied metal finish to the surface of the pins. The plating layer comes in just few microns of thickness normally from 0.1 to 0.5 mcrns affecting medium duty and cost on each pin
The next step is to color the pin by filling the raised surfaces with enamel. Soft enamel and hard enamel are two most common style of enamels As the name suggests, soft enamel has a more recessed look than hard because after all of the details are filled in with color- they will be air dry which then leaves a metal edge thats raised just slightly flush to whatever color is on your coin/ patch. Hard enamel, on the other hand, is subjected to temperatures of around 450 degrees Fahrenheit in order for it to become hard and then polished smooth with a metal surface providing you with an attractive glossy outcome. With multiple colors even more rings of coloring could be needed on each pin.
Finally, the pins are polished and controlled. Polishing: This is the final process to remove any imperfections such as sharp edges, etc., and also makes sure that lapel pin surface should be smooth and gleaming out. There are a series of quality control checks that look the metal, plating, and coloring… only those with absolutely perfect pins get to pass inspection. Bad pins could be recycled, melting down the metal and using it in future batches.
So in conclusion, there is a precise process to designing and eventually creating lapel pins. Every stage, from stamping or die-casting to plating and coloring, matters when producing a finished pin of the proper size/shape/design durability. With this attention to detail lapel pins, not only can these be a real sight but also last for many years after which may come out as valuable collector items or giveaway promotional products.