Custom challenge coins are made from zinc alloy, brass, iron or copper, then plated in a separate finish such as gold, silver, nickel or antique.

What each suits:

  • Zinc alloy. The most common base for die-cast coins. It handles complex shapes, cutouts and 3D relief well, because it is cast rather than struck. Good detail retention and a substantial weight.
  • Brass. A die-struck option with a dense, solid feel and excellent detail on fine linework. A traditional choice for coins with engraved detail and antique finishes.
  • Iron. A cost-effective struck option, well suited to larger quantities and simpler designs.
  • Copper. Struck, with a warm tone that works particularly well under antique and polished copper finishes.

The base metal is usually chosen for you as part of the quote, based on the design rather than as a separate decision. A coin with a custom outline and cutouts will typically be cast in zinc alloy; a flat coin with fine engraving may be struck in brass.

What you see on the surface is the plating rather than the base metal. A gold challenge coin is gold plating over one of the metals above, not solid gold.

See manufacturing options or request a free quote and we’ll recommend the right base for your design.