Overview
The Karlach hard enamel pin is a bold tribute to fantasy character design, brought to life in a 3-inch, gold-plated, hard enamel format. Designed for fans of powerful heroines and epic aesthetics, this collectible piece features a horned warrior exuding confidence, surrounded by flames that enhance her fierce persona. With premium materials and meticulous craftsmanship, this pin is more than merchandise — it’s a statement piece for fans and collectors alike.
Pin Design Details
Key details included:
- A pin (3 inches tall) to capture detailed character features
- Use of gold plating to provide a luxe finish
- Hard enamel process for a smooth, polished surface with strong color retention
- Inclusion of silkscreen printed details for facial expression and accessories
- Use of translucent enamel to add visual contrast and depth
- Reinforced backing with three rubber clutches for secure attachment
Crafting Process & Technical Details
Mold Creation and Blank Forming
The journey began with the development of a precision-cut steel mold based on the client’s vector artwork. This mold defines all raised and recessed areas of the pin — from flame outlines to facial details — and is the foundation for every physical pin blank.
Next, blanks were created by mold. Each blank precisely mirrored the character’s silhouette, including internal cutouts where needed.
Filling Colors & QC
With the base formed, enamel color filling began. Using Pantone-matched hard enamel paints, each recessed area on the pin was filled by hand with a syringe. Each color had to be applied separately and baked in a kiln between layers to permanently set the enamel. This included:
- Rich reds and oranges for the flame accents
- Deep blacks and gunmetal tones for armor
- Metallic tints for embellishments
Of course, each pin underwent strict quality control.
Wet grinding & Sent for Printing
After all colors were baked and cured, each pin went through wet grinding — a process where the surface is polished using water and fine abrasives to ensure the enamel is flush with the metal lines. This step is essential in achieving the smooth, glass-like finish hard enamel is known for.
Once the enamel layer was perfected, the pins were sent for silkscreen printing. This added intricate facial details, tattoos, and weapon textures with ultra-precision. These printed elements elevated the character’s expression and gave the design extra depth.
Final Assembly & Completion
After passing inspection, each pin was outfitted with three black rubber clutches for stability. The back was engraved with the client’s branding and character silhouette for collector appeal. Once packaging was complete, every pin was sealed in a PVC bubble bag for protection during delivery
“The production team didn’t miss a single detail — from enamel fill to polish, every piece felt like a finished art object,” shared the client.
From Draft to Reality
Our production team collaborated closely with the client at every step:
- Initial Vector Artwork: Clean, high-resolution files were submitted by the client.
- Proofing Stage: Digital mockups showed pin layout, color codes, plating, and transparent effects for approval.
- Sampling: A pre-production sample was created to test balance between enamel and print areas. Adjustments were made for clarity and depth.
- Mass Production: Once approved, over 55 pieces were produced with strict quality control checks on polish, fill, and color accuracy.
Packaging & Finishing
Each pin was packaged in a PVC bubble wrap pouch to prevent scratches during shipping. For secure wearing, three rubber clutches were applied — ideal for large-format pins to prevent shifting or rotation.
“We were impressed by the finish — the balance between print and enamel came out beautifully. It’s smooth, solid, and looks exactly how we imagined,” the client said.
Market Impact & Fan Reaction
Following its release, the Karlach pin quickly gained popularity among fantasy enthusiasts, particularly those drawn to bold, expressive characters. It sold out of its initial run within weeks, with many fans praising its:
- Unique fire-inspired composition
- Smooth, high-gloss finish
- Durable feel and vibrant colors
Conclusion & Call to Action
The Karlach hard enamel pin is proof of how high-quality craftsmanship can elevate fan merchandise into premium collectibles. From initial sketches to polished final product, this project blended artistic vision with production precision.
Looking to bring your own fantasy or fandom characters into the world of enamel collectibles?
📩 Let’s collaborate! Reach out to us to turn your vision into an eye-catching, professionally crafted enamel pin — perfect for fans, creators, and boutique retailers alike.