Challenge coins are widely used across the UK for military recognition, club memberships, company branding, commemorative events, and personalised gifts. Today, there are several ways to create custom challenge coins, ranging from traditional metalworking techniques to modern digital fabrication methods.
Each approach differs in cost, production speed, design flexibility, and skill requirements. In this guide, we compare four popular challenge coin-making methods—electric tools, CNC machining, 3D printing, and laser engraving to help you choose the best option for your project. We'll also explain why laser engraving has become a preferred solution for hobbyists, small businesses, and custom makers.
In this article:
Method 1: Make Challenge Coins with Electric Tools
Using electric tools is one of the most accessible ways to create custom challenge coins at home or in a small workshop. This method is popular among hobbyists and DIY makers because it requires relatively simple equipment and works with a variety of materials, including wood, acrylic, resin, and certain soft metals.
While electric tools offer greater control and efficiency than fully manual methods, they still rely heavily on the user's skill. As a result, they are best suited to one-off projects, personalised gifts, commemorative keepsakes, and club tokens rather than high-volume production.
Materials and Tools Needed
Before starting, gather the following materials and equipment:
- Wood, acrylic, resin blanks, or soft metal discs
- Rotary tool or Dremel
- Drill or drill press
- Orbital sander or sandpaper
- Engraving bits or metal stamps
- Paint, enamel, or metallic finishes
- Polishing cloth or buffing wheel
- Ruler, calipers, or measuring tools
- Safety glasses and protective gloves
Steps to Make Challenge Coins with Electric Tools
- Prepare the Coin Blank: Select a blank made from wood, acrylic, resin, or soft metal. The material should be cut to the desired diameter and thickness before engraving begins.
- Shape the Coin: Use a rotary tool, cutting attachment, or sander to refine the edges and create a smooth, uniform coin shape. Consistent dimensions help improve the final appearance.
- Create the Design Layout: Prepare the artwork for the challenge coin. This may include logos, military insignia, club emblems, names, dates, or decorative patterns. Printing the design beforehand can help improve accuracy.
- Engrave the Details: Carefully engrave the design using rotary engraving bits or metal stamps. Depending on the material, multiple passes may be needed to achieve sufficient depth and visibility.
- Apply Decorative Finishes: Enhance the design with paint, enamel filling, metallic coatings, or coloured accents. These finishing touches can improve contrast and make the engraved details stand out.
- Polish the Surface: Buff the finished coin using a polishing cloth or buffing wheel to remove minor scratches and create a cleaner, more professional appearance.
Advantages
- ✓ Low equipment cost compared with industrial manufacturing
- ✓ Suitable for beginners and DIY enthusiasts
- ✓ Works with multiple materials
- ✓ Good option for personalised or commemorative projects
Limitations
- ✗ Precision depends heavily on operator skill
- ✗ Fine details can be difficult to reproduce consistently
- ✗ More manual finishing is required
- ✗ Not ideal for producing large quantities of identical coins
Best For
- DIY hobby projects
- Club tokens and membership coins
- Cosplay props and accessories
- Personalised gifts
- Small-scale commemorative coins
Difficulty Level
Beginner to Intermediate
Final Verdict
Electric tools offer an affordable entry point into challenge coin making and are well suited to occasional DIY projects. However, achieving professional-grade detail and consistent results can be challenging. For makers who want higher precision, faster production, and cleaner engraving quality, CNC machines and laser engravers provide more advanced alternatives.
Method 2: Make Challenge Coins with a CNC Machine
A CNC machine is one of the most precise methods for producing custom challenge coins. Unlike manual engraving techniques, CNC routers and desktop engraving machines use digital design files to carve intricate logos, text, and decorative patterns with a high level of consistency.
This approach is commonly used for military-style challenge coins, commemorative keepsakes, club emblems, branded promotional coins, and small-batch production runs. CNC machining can also achieve deeper engraving and sharper edge definition, making it a popular choice for makers seeking a more professional finish.
Materials and Tools Needed
To create challenge coins with a CNC machine, you will typically need:
- CNC router or CNC engraving machine
- Wood, brass, aluminium, acrylic, or resin blanks
- CAD or vector design software
- CNC control software
- Engraving or carving bits
- Clamps or work-holding fixtures
- Sandpaper or polishing tools
- Paint, enamel, or metallic finishes (optional)
- Safety glasses and hearing protection
Steps to Make Challenge Coins with a CNC Machine
- Design the Challenge Coin: Create the artwork using CAD or vector software. This can include logos, military insignia, club emblems, text, borders, and decorative elements.
- Prepare the Coin Blank: Secure the chosen material onto the CNC machine bed using clamps or fixtures. Proper positioning is essential for accurate engraving.
- Configure the Toolpath: Import the design into the CNC software and adjust engraving depth, feed rate, spindle speed, and cutting parameters according to the material.
- Engrave the Design: Run the engraving programme to carve the design into the surface of the coin. Multiple passes may be used for deeper relief effects.
- Cut the Coin Shape: Where required, use the CNC machine to cut the outer profile and create a clean circular edge.
- Apply Decorative Finishes: Enhance the appearance with enamel filling, metallic coatings, paint accents, or protective finishes.
- Polish the Surface: Polish the finished coin to improve clarity, surface quality, and overall presentation.
Advantages
- ✓ Excellent engraving precision and detail
- ✓ Consistent results across multiple coins
- ✓ Suitable for wood, acrylic, resin, and metal materials
- ✓ Capable of creating deep relief designs
- ✓ Ideal for small-batch production
Limitations
- ✗ Higher equipment investment than manual methods
- ✗ Requires CAD and CNC software knowledge
- ✗ Longer setup time before production
- ✗ Steeper learning curve for beginners
- ✗ Production speed can be slower than modern laser engraving workflows
Best For
- Military-style challenge coins
- Club and membership coins
- Corporate promotional coins
- Small-batch manufacturing
- Detailed metal engraving projects
Difficulty Level
Intermediate to Advanced
Final Verdict
CNC machining delivers highly accurate and professional-looking challenge coins, particularly for projects that require deep engraving or detailed relief effects. However, the higher equipment cost and technical learning curve may not suit every maker. For users looking for a faster workflow, easier operation, and versatile material compatibility, laser engraving can often provide a more efficient alternative.
Method 3: Make Challenge Coins with a 3D Printer
3D printing offers one of the most flexible ways to create custom challenge coins, particularly for makers who want complete design freedom. Rather than engraving a design into a material, a 3D printer builds the coin layer by layer from a digital model, making it possible to produce intricate logos, raised details, unique edge profiles, and multi-level designs.
This method is especially popular for cosplay props, gaming collectibles, commemorative tokens, club emblems, prototype designs, and display pieces. It is also an excellent option for testing new challenge coin concepts before moving to more permanent manufacturing methods.
Materials and Tools Needed
To make challenge coins with a 3D printer, prepare the following:
- 3D printer
- PLA, PETG, resin, or metallic-effect filament
- 3D modelling software or STL design files
- Slicer software
- Sandpaper or deburring tools
- Primer, metallic paint, or enamel finishes
- UV curing station (for resin printers)
- Protective gloves and face mask
Steps to Make Challenge Coins with a 3D Printer
- Create the Coin Design: Design the challenge coin using 3D modelling software or download a suitable STL file. Include logos, text, borders, and decorative features as required.
- Prepare the Print File: Import the model into slicing software and adjust settings such as layer height, infill density, print speed, and support structures.
- Load the Printing Material: Install the chosen filament or resin and ensure the printer is properly calibrated for accurate printing.
- Print the Challenge Coin: Start the print and monitor the first few layers to ensure good adhesion and dimensional accuracy.
- Remove and Clean the Print: Carefully remove the coin from the build plate and remove any support structures or excess material.
- Sand and Refine the Surface: Use sandpaper or finishing tools to smooth visible layer lines and improve the overall appearance.
- Apply Decorative Finishes: Add primer, metallic paint, enamel details, or weathering effects to create a more realistic challenge coin appearance.
Advantages
- ✓ Highly customisable designs
- ✓ Suitable for complex shapes and raised details
- ✓ Easy to reproduce multiple identical coins
- ✓ Excellent for prototypes and concept testing
- ✓ Supports creative and unconventional coin designs
Limitations
- ✗ Visible layer lines often require post-processing
- ✗ Metallic finishes typically require painting
- ✗ Surface durability varies by material
- ✗ Fine details depend heavily on printer quality and settings
- ✗ May not achieve the authentic appearance of engraved metal challenge coins
Best For
- Cosplay accessories
- Gaming collectibles
- Prototype challenge coins
- Display and decorative pieces
- Design concept validation
Difficulty Level
Beginner to Intermediate
Final Verdict
3D printing is a versatile solution for creating custom challenge coin prototypes, display pieces, and highly creative designs. However, achieving a premium metallic appearance often requires additional finishing work. For makers seeking sharper engraving, professional presentation, and durable customisation on real materials, laser engraving is typically the more practical choice.
Method 4: Make Challenge Coins with a Laser Engraver
Laser engraving is one of the most precise, efficient, and beginner-friendly methods for creating custom challenge coins. Unlike manual engraving or CNC machining, a laser engraver follows a digital design file to produce highly detailed logos, text, serial numbers, borders, and decorative artwork with exceptional consistency.
For makers, small businesses, collectors, and workshop owners in the UK, laser engraving offers an excellent balance of precision, speed, material compatibility, and ease of use. It is particularly well suited to personalised challenge coins, military-style coins, commemorative tokens, club emblems, branded promotional pieces, and limited production runs.
Materials and Tools Needed
To create challenge coins with a laser engraver, you will need:
- Laser engraver
- Stainless steel, brass, aluminium, acrylic, leather, or coated metal blanks
- Vector design software
- Masking tape (optional)
- Polishing cloth or buffing tools
- Paint filling or enamel finishes (optional)
- Ventilation or smoke extraction system
- Safety glasses
Steps to Make Challenge Coins with a Laser Engraver
- Create the Coin Design: Design the artwork using vector software. Logos, military insignia, club emblems, names, decorative borders, and serial numbers can all be engraved with high accuracy.
- Prepare the Coin Blank: Position the challenge coin blank securely in the engraving area and ensure proper alignment before starting.
- Configure the Laser Settings: Adjust laser power, speed, frequency, and engraving depth according to the selected material.
- Engrave the Design: Start the engraving process and allow the laser to permanently mark the design with sharp detail and clean edges.
- Apply Decorative Finishes: Optional paint filling, enamel colouring, or metallic finishes can be used to increase contrast and visual appeal.
- Polish the Coin: Clean and polish the finished coin to achieve a professional presentation.
Advantages
- ✓ Exceptional engraving precision
- ✓ Fast production speeds
- ✓ Permanent, high-contrast marking
- ✓ Suitable for both one-off and batch production
- ✓ Works on a wide range of metal and non-metal materials
- ✓ Minimal post-processing compared with CNC machining or 3D printing
Limitations
- ✗ Initial machine investment required
- ✗ Certain bare metals achieve the best results with fibre laser technology
- ✗ Deep embossing effects may require multiple engraving passes
Best For
- Military challenge coins
- Commemorative coins
- Corporate branding projects
- Club and membership tokens
- Personalised gifts
- Small business customisation services
Difficulty Level
Beginner to Intermediate
Final Verdict
Among all four methods, laser engraving offers the best balance of precision, speed, ease of use, and production efficiency. It produces professional-quality challenge coins on real materials while avoiding many of the setup complexities associated with CNC machining and the finishing requirements often seen with 3D printing.
Recommended Laser Engraver for Challenge Coin Projects: LaserPecker LP5
The LaserPecker LP5 is an excellent choice for makers, engraving businesses, collectors, and workshop users who need professional-quality challenge coin engraving across a wide range of materials.
Its 20W Fibre Laser and 20W Diode Laser combination allows users to engrave stainless steel, brass, anodised aluminium, coated metals, acrylic, leather, wood, and many other commonly used challenge coin materials with outstanding detail and efficiency.
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20W Fibre + 20W Diode Dual-Laser System
Engrave both metal and non-metal challenge coin materials using a single compact machine. -
Up to 10,000 mm/s Engraving Speed
Quickly produce detailed logos, military insignia, serial numbers, and decorative artwork. -
0.0027 mm Engraving Precision
Create crisp lettering, clean borders, and highly detailed coin designs with professional accuracy. -
120 × 160 mm Working Area
Provides sufficient space for engraving multiple challenge coins in a single production session. -
Compact Desktop Design
Ideal for home workshops, craft studios, event customisation services, and small businesses. -
Enhanced Workshop Safety
When paired with the LaserPecker LP5 Safety Enclosure, the system achieves Class 1 Laser Safety, making it particularly suitable for users who prioritise safety in home or workshop environments.
For indoor engraving applications, the LaserPecker Desktop Smoke Purifier can effectively filter smoke, odours, and airborne particles generated during engraving and cutting, helping maintain a cleaner and more comfortable workspace. -
Broad Material Compatibility
Supports stainless steel, brass, anodised aluminium, coated metals, acrylic, leather, wood, and many other engraving materials commonly used in challenge coin production.
FAQs: Hot Questions about Making Challenge Coins
Q1: What Are Challenge Coins Used For?
Challenge coins are commonly used for military recognition, club memberships, company branding, commemorative events, fundraising campaigns, and collector communities. In the UK, they are also popular as personalised gifts and custom keepsakes for organisations, sports clubs, and special occasions.
Q2: What Materials Are Used to Make Challenge Coins?
Challenge coins can be made from brass, copper, zinc alloy, stainless steel, aluminium, acrylic, wood, and resin.
Brass and zinc alloy are often chosen for their affordability and ease of production, while stainless steel offers greater durability and a modern appearance. Acrylic and wood are popular among hobbyists using laser engravers.
Q3: What Size Are Most Challenge Coins?
Most challenge coins measure between 38 mm and 50 mm in diameter, which is roughly equivalent to 1.5–2 inches.
However, custom challenge coins can be produced in a wide range of sizes depending on the design complexity, intended use, and display requirements.
Q4: Can You Make Challenge Coins at Home?
Yes. Modern desktop fabrication tools make it possible to create challenge coins at home using electric engraving tools, CNC machines, 3D printers, or laser engravers.
Among these options, laser engravers are often preferred because they offer a combination of precision, speed, and ease of use.
Q5: How Thick Should a Challenge Coin Be?
Most challenge coins are between 2 mm and 4 mm thick.
Thicker coins generally feel more substantial and premium, while thinner designs are lighter and easier to carry or distribute at events.
Q6: What Is the Best Machine for Making Challenge Coins?
The best machine depends on the materials and level of detail required.
For hobby projects, electric tools may be sufficient. For deep metal carving, CNC machines are a strong option. However, for most users seeking professional-quality engraving, fast production, and broad material compatibility, a laser engraver offers the best overall balance.
Q7: Can a Laser Engraver Engrave Metal Challenge Coins?
Yes. Fibre laser systems can engrave stainless steel, brass, anodised aluminium, and many coated metals with exceptional precision.
Dual-laser systems such as the LaserPecker LP5 can also support both metal and non-metal challenge coin materials, making them highly versatile for custom projects.
Q8: How Much Does It Cost to Make Custom Challenge Coins?
The cost varies depending on the production method, materials, and quantity.
DIY challenge coins made at home may cost only a few pounds per piece, while professionally manufactured metal challenge coins can cost significantly more. Laser engraving is often one of the most cost-effective options for producing small batches of customised coins.
Conclusion
Making challenge coins has never been more accessible, with options ranging from DIY electric tools and 3D printing to professional CNC machining and laser engraving.
While each method has its advantages, laser engraving offers the best balance of precision, speed, material compatibility, and ease of use for most makers and small businesses. Whether you're producing military-style challenge coins, commemorative keepsakes, promotional tokens, or personalised gifts, a laser engraver can deliver professional-quality results with minimal setup and consistent repeatability.
For users seeking versatility and efficiency, the LaserPecker LP5 is a particularly strong choice.
