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A custom pin is a metal craft product that goes through multiple production processes. Things like color matching, special effects and polishing still require manual adjustment during manufacturing. Because of this, it is difficult to make a pin that is 100% identical to the original design.
However, if you can confirm some important details with the factory before production — such as cut-out areas, colors, size, thickness, and the number of pin posts — the final product can be much closer to the original artwork.
Here are some details you should pay attention to before placing your order.
Cut-out Areas
Cut-out areas are one of the details that many customers overlook when designing custom pins.
Sometimes, when our representatives receive a design, they can immediately tell customers that certain parts may not be able to achieve the same effect as shown in the artwork. Large cut-out areas usually do not create major problems. The main issue happens with extremely small hollow areas. The smallest cut-out size that our factory machines can usually produce is around 0.4mm or larger. If the metal lines around the cut-out area are too thin, there is also a risk that the structure may break during production.
This situation is actually very common for logo pins, especially designs with small letters or detailed symbols. We once had a customer from Belgium who wanted to create a logo pin with hollow areas inside the letters “B” and “P”. They asked us about the possible size limitations of the cut-out parts before production. Then our rep gave them the suitable size.
So always confirm it with the factory before production starts.
If the factory cannot create a fully through-hole cut-out, they may suggest using recessed cutting instead. This means the metal surface will still have a recessed area, but the metal underneath will remain connected. Recessed areas do not have the same minimum size requirement. You should understand that the final pin will have an extra metal surface compared with the original design.
If this solution is not ideal for you, you can also discuss other options with the factory. For example, increasing the overall pin size can often help solve this problem.
Design Complexity
When a design contains complicated patterns, small text, or very thin lines, the final pin product may look different from the original artwork.
This happens especially with hard enamel pins.
Hard enamel pins require metal borders to separate different color areas. If the original design contains very thin lines, the metal borders may need to become slightly thicker during production. As a result, some details may appear heavier or less delicate than the original design.
In these situations, we usually recommend two solutions:
The first option is switching to soft enamel pins. It can handle some detailed designs better.
The second is adjusting the artwork before production. Maybe you can increase thin lines to around 0.2mm or redesign certain details to make them more suitable for pin manufacturing.
Enamel Pin Colors
You may have heard many times that enamel colors are usually matched based on Pantone references. The final product may look slightly different from what you see on a computer screen.
One good way to reduce the difference is to choose colors that are already close to Pantone colors when creating your design.
You can use the color selector on Factorypin to find the closest Pantone color and use it directly in your artwork.
For designs with complex gradients, Pantone colors may not always be the best reference. It’s usually better to compare the design with a CMYK color chart.
Size and Thickness
For most custom pins, a size around 3.5cm (1.5 inches) can already meet the needs of most customers. Pins of this size are usually produced using stamping processes. They can achieve a moderate 3D effect, but the depth is relatively limited, and there are usually fewer opportunities for complex cut-out designs.
However, if you need a much larger pin, such as 3-inch or 4-inch pins, the production method may need to change.
Larger pins often require a die-casting process. The mold cost is higher compared with traditional stamping, but it allows the factory to create much more three-dimensional structures. With die casting, the pin thickness can reach around 10mm, and the design can include multiple layers, deeper 3D effects, and more complicated cut-out structures.
Pin Post Placement
The number and position of pin posts are usually related to the size and shape of the badge.
For pins smaller than 1 inch, placing one pin post in the center is enough to keep the pin stable.
For larger pins, you need to consider the width and height of the design. A simple rule is: Place the pin posts based on the direction where the badge is larger.
By choosing the right pin post placement, you can avoid problems such as the pin rotating, tilting, or falling from clothing.
Choosing the Right Custom Pin Type
| Pin Type | Look & Feel | Best For | Cost | Production Time |
|---|---|---|---|---|
| Soft Enamel Pin | Textured, raised metal outlines | Schools, sports teams, souvenirs | Affordably priced, low to medium | 2 weeks |
| Hard Enamel Pin | Smooth, jewelry-like finish | Corporate branding, high-end giveaways | Medium to high, more expensive than soft enamel | 3-5 weeks |
| Die Struck Pin | Classic, no color, metallic look | Awards, recognition, achievements | Affordably priced, medium | 3 weeks |
| Offset Printed Pin | Photorealistic, full-color designs | Logos, photographs, intricate artwork | Affordable, medium to high | 1-2 weeks |
| 3D Cast Pin | Sculpted, dimensional effect | Corporate gifts, high-detail designs | High, due to molding process | 3-4 weeks |
Still Not Sure?
The closer the communication between the designer and the factory, the closer the final pin will be to the original design. A professional pin manufacturer can help identify potential issues early and provide suggestions to achieve the best possible result.
Whether you are creating custom pins for a corporate event, a club, a brand, or a personal project, Factorypin is here to help turn your ideas into high-quality finished products.
