Metal cast challenge coin and mold

thingiverse

This is a 45 mm diameter, 5mm thick challenge coin and mold designed for casting reusable silicone molds in metal. The project involves creating a MoldMold that has already been used to produce 15 coins with no issues so far. Background I was inspired by the episode of podcast *99% Invisible* where they explored Challenge Coins. Last year, I had my own minted through an online service, using zinc material. To get a good price, I ordered 300 coins, paying $3.50 per coin. However, this led to high die fees. Then I came across a casting project and decided to print and cast my own coins. The total cost includes $4 in PLA, $6 in molding silicone, and $1.30 in metal per coin. I also spent 50 hours designing and printing the molds and about .5 hrs per finished coin at no charge for my time. The details printed by my printer were impressive, and they transferred well to the final coins. The finished products are straight from the mold with no sanding or buffing required. However, the edges of the coin have a slightly uneven look due to compression during the molding process. This imperfection gives my handmade coins a unique touch that separates them from mass-produced tokens like those at Chuck E Cheese's.