Overview
This project spotlights a custom enamel pin set inspired by two well-known characters from the Star Wars universe — Ahsoka Tano and the Grand Inquisitor. Created for a collector community event, the pin set utilizes hard enamel (imitation cloisonné) craftsmanship to present a high-end collectible quality. The client’s goal was to produce a vibrant, polished pin set with smooth surfaces and premium packaging for limited distribution.
Client Requirements
The client emphasized the following key requirements:
- Hard enamel finish for a smooth, polished feel and long-term durability.
- A detailed character design faithful to the original animated series.
- Electroplated gold finish for an upscale aesthetic.
- PVC bag with bubble wrap for individual protective packaging.
- Dual-post black rubber clutches for secure attachment.
The pin was to measure approximately 2.5 inches in height, composed of thick metal (2.5mm) for a substantial feel in hand.
Crafting Process
Material Selection & Molding
The product was created using zinc alloy, ideal for larger pins due to its stability and molding flexibility. Zinc alloy allowed for intricate detailing—especially important for Ahsoka’s facial features and the Grand Inquisitor’s robes.
Enamel Application
The imitation enamel process was chosen over soft enamel to provide a flat, glassy surface. Each color—matching the Pantone color codes like 7486 (blue), 292 (light blue), and 472 (tan)—was carefully filled and kiln-cured to ensure long-lasting vibrancy and no bleeding between segments.
Polishing & Electroplating
After curing, the pins underwent multiple rounds of polishing to achieve the hallmark luster of hard enamel products. The surface was then electroplated in imitation gold, which enhanced both the contrast and perceived value of the characters against the enamel background.
Client Interaction Highlights
The client was particularly specific about color accuracy, especially in the characters’ skin tones and clothing. Several rounds of sample proofing were conducted before the design was approved. The client noted:
“The color fill and metal polishing exceeded expectations—absolutely thrilled with the accuracy of the facial details.”
We also ensured the back side featured custom laser-etched text, including a logo and limited-edition numbering (“UE25”), to align with the collector’s edition feel.
Production Workflow
- Artwork Finalization – Client submitted vector files and reference screenshots.
- Die Creation – Mold and cut-line tools were developed and approved.
- Color Matching – Pantone colors selected and tested on sample plates.
- Enamel Filling – Liquid hard enamel was injected into recessed areas.
- Curing and Polishing – Repeated curing/polishing cycles ensured durability and flatness.
- Plating – Gold finish applied post-polishing for consistency.
- Backstamp & Posts – Custom engraving and dual rubber posts soldered.
- Quality Check – Each pin individually inspected and packaged.
Post-Production Details
The pins were packed in PVC bags with bubble wrap, ensuring protection during international shipment. Despite the complexity of the design, the entire production timeline was kept within a 20-day turnaround window.
Additionally, the back of the pin includes the etched phrases:
- “Enchanted Pins for Guardians of the Stars”
- “UE 25”
This etching emphasized the collector value while allowing for easy authenticity verification.
FAQ
Q: What makes hard enamel different from soft enamel?
A: Hard enamel has a smooth surface achieved through polishing after enamel curing. It feels glass-like and is highly durable. In contrast, soft enamel is recessed and has a textured surface.
Q: Can we do custom character pins with licensed content?
A: Only with proper licensing or permission. In this case, the pins were created for private collection and not for resale.
Q: What is the minimum order quantity for hard enamel pins?
A: This project started at 25 units, which is on the lower end thanks to our efficient mold-sharing setup. Standard MOQ is typically 100+.
Q: Why was zinc alloy used instead of copper?
A: Zinc alloy allows for cost-effective production of large-format pins (2.5”+), without sacrificing mold clarity or stability.
Q: Can hard enamel pins include glitter or translucent fills?
A: Yes, we can incorporate glitter, glow-in-the-dark, and stained glass enamel as well, depending on design feasibility.
Conclusion
This Ahsoka Tano and Grand Inquisitor enamel pin exemplifies the best of modern pin craftsmanship—precision, durability, and high-end appeal. From exacting Pantone fills to collector-grade packaging, every aspect was meticulously managed. The client expressed strong interest in expanding the series to include more characters due to the overwhelmingly positive reception.