Behind the Great Wall: Inside a Challenge Coin Factory
A first-hand look at how challenge coins are engineered, machined, and produced in China
This past week, I traveled to our production facility in Bengbu, China, to see firsthand how challenge coins are actually made inside a real challenge coin factory.
After flying into Shanghai, we drove more than 300 miles inland toward Bengbu. Along the way, we stopped for the night in Nanjing—the former capital of China. It was Spring Festival weekend, and the city was packed with people celebrating in the streets.
I stood out immediately. In many cases, I was the only Westerner around, and families were stopping to take pictures with the big white guy. It was unexpected—but the people were incredibly friendly and welcoming.
The next day, we continued on to Bengbu.
When we arrived, it was clear what this city represents. Bengbu is surrounded by industrial production—factory after factory—and shows exactly why China has become a global manufacturing powerhouse.
And right in the middle of that is where our coins are made.
For more than nine years, I’ve worked in challenge coin design and production. But seeing the full process in person gave me a completely new appreciation for what it takes to turn an idea into a finished coin.
What Most Customers Never See
Most people have no idea what happens inside a challenge coin factory.
From the outside, the process looks simple:
You contact a coin company, finalize your design, approve the artwork, and a few weeks later your coins arrive.
What you don’t see is everything in between.
Engineering. CNC machining. Die creation. Finishing. Inspection.
A challenge coin is not just made—it goes through a detailed challenge coin manufacturing process that requires precision at every step.
What follows is a step-by-step breakdown of how challenge coins are made, based on what I witnessed firsthand.
1. Art Department
Every coin starts in the art department.
Once a design is approved, it is refined and converted into a vector file that can be used in production.
This is not just graphic design—it’s engineering.
Artwork must be adjusted to work in metal:
- Line thickness
- Depth
- Raised vs recessed areas
- Text clarity
This stage ensures the design can actually be manufactured.
2. CNC Art Preparation
Next, the design moves into CNC preparation.
This is where the artwork becomes physical.
Depth is assigned. Relief is mapped. Every detail is prepared for machining.
For 3D coins, this step is critical. The way a coin feels in your hand is determined here—not later.
3. CNC Machining the Die
The die is then machined using CNC equipment.
This die is what physically creates the coin.
- 2D dies: ~2+ hours per side
- 3D dies: ~5.5+ hours per side
Every detail must be perfect, because whatever is on the die will appear on every coin produced.
4. Die Heat Treatment
After machining, the die is hardened through heat treatment.
This strengthens the die so it can withstand repeated use without losing detail.
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5. Coin Stamping or Injection Molding
Now the coin begins to take shape.
Most coins are made from zinc:
- 2D coins → stamped using high-pressure machines
- 3D coins → created using molten zinc injection
At this stage, the coin is formed—but still unfinished.
6. Coin Cleaning
Coins are cleaned to remove oils and debris from production.
This prepares them for finishing and ensures quality.
7. Electroplating
We traveled to a separate facility to see this process.
Each coin is dipped into chemical solutions that apply finishes such as:
- Antique gold
- Antique silver
- Nickel
- Copper
This is what gives the coin its final metal appearance.
8. Polishing
Coins are polished to create contrast.
Raised areas shine, recessed areas remain darker.
This is what gives a coin depth and visual impact.
9. Painting / UV Application
Color is applied either by hand or machine.
- Hand-painted coins require extreme precision
- Machines can paint 30 coins at once
This is one of the most detail-sensitive stages in the entire process.
10. Oven Drying
Coins are placed into ovens to cure the paint.
This ensures durability and long-term quality.
11. Final Inspection and Shipping
Each batch is inspected for:
- Finish quality
- Paint accuracy
- Detail consistency
Once approved, coins are packaged and shipped.
What It Really Takes
The full process takes over 10 days.
More than 100 workers are involved.
Each coin represents over 100 hours of combined work. This is our PRODUCTION PIPELINE.
Why This Matters
A high-quality challenge coin does not happen by accident.
It is the result of a controlled, engineered process.
Most customers only see the finished product—but understanding the process explains why quality varies so much between coin companies.
At Excalibur Industries, we focus on this process from start to finish.
We don’t just make coins.
We engineer them.
John Joyce is a former U.S. Army Special Forces Communications Sergeant and Police Officer, and the Founder & Lead Coin Engineer at Excalibur Industries, specializing in precision-engineered challenge coins for military, government, and corporate clients.
