Custom Challenge Coins Pricing — 2026 Cost Breakdown by Size & Finish

For a 1.75-inch zinc alloy coin, 2D design, antique gold plating, no colour fill:

• 50 pcs: USD 5.90 – 7.20 per coin (mold USD 120)
• 100 pcs: USD 3.40 – 4.30 per coin (mold USD 120)
• 250 pcs: USD 2.55 – 3.10 per coin (mold waived)
• 500 pcs: USD 2.05 – 2.60 per coin
• 1,000 pcs: USD 1.60 – 2.05 per coin
• 2,500+ pcs: USD 1.35 – 1.75 per coin

1. Size and thickness. 1.5 inch is the entry standard; 2 inch adds roughly 18% material and plating cost. Thickness moves from 3 mm standard to 4 mm premium.

2. Plating. Antique gold, antique silver and antique bronze are standard. Black nickel, dual plating and rose gold add USD 0.15–0.35 per coin.

3. Colour fill. Soft enamel fill is included up to 4 colours; each additional colour adds USD 0.08. Hard enamel, which is polished flush with the metal, adds USD 0.45–0.70 per coin but produces the premium jewellery finish military units prefer.

4. 3D versus 2D. A 3D sculpted coin requires hand modelling and adds USD 180–320 to tooling plus USD 0.30–0.55 per coin.

5. Edge and extras. Reeded edges, cut-outs, sequential numbering, spinning centres and bottle-opener edges each add USD 0.20–0.85 per coin.

Free digital artwork and unlimited revisions, free physical sample, standard poly bag packaging, and a 24-month free mold storage window. There is no artwork fee, no setup fee beyond tooling, and no charge for revisions before production.

Keep the coin at 1.5 inch, use 2D relief with soft enamel rather than full 3D, limit to 4 colours, and choose antique plating over dual plating. That combination typically lands at USD 2.10 per coin at 250 pieces — and looks identical to a USD 4 coin at arm’s length.

For military and first responder units, see our challenge coin manufacturing page.