Overview
The Aurora and Philip project is an intricate two-piece pin that merges the classic elegance of hard enamel craftsmanship with the visual depth of high-resolution printing. This design features a detailed floral wreath, rendered in polished gold-plated metal and rich enamel colors, surrounding a separate printed scene of the two titular characters. The structure is a pin-on-pin (pinonpin) format, meaning two distinct pins are manufactured and then assembled into one finished product. This not only elevates the visual appeal but also allows the use of different production techniques for maximum fidelity in both the frame and the illustration.

Client Requirements
Our client envisioned a pin that would serve as a premium collectible item, ideal for gifting and retail display. The requirements included:

• Gold-plated finish with a flawless, mirror-like polish.
• A durable hard enamel outer frame to highlight the floral design.
• A photorealistic inner scene capturing soft gradients and delicate expressions.
• Incorporation of special effects—clear glitter accents and sandblasted textures.
• Two posts on the back for balance and wear stability, with rubber clutches.
• Packaging suitable for both online orders and physical store sales.

Key Design Decisions and Challenges
Creating Aurora and Philip required a balance between traditional pin craftsmanship and modern print technology.

1. Hard enamel for the frame – This choice ensures vivid, solid colors with a smooth surface flush to the gold outlines. The polished finish enhances the premium feel.
2. Printed insert for the scene – Offset printing allows for fine details, skin tone accuracy, and color gradients impossible with enamel alone.
3. Pin-on-pin assembly – By making the frame and printed scene separately, each could undergo its optimal finishing process before being joined.
4. Effect integration – Glitter and sandblast effects needed to be applied with precision so they enhanced the design without overpowering the central illustration.

Two Special Effects in the Artwork

• Clear glitter over translucent enamel – The floral wreath featured areas where a soft sparkle was desired. We mixed translucent enamel with fine glitter, ensuring the glitter particles caught the light without obscuring underlying color.
• Sandblasted or frosted metal texture – Certain recessed petals and background elements required a matte contrast. We achieved this by selectively sandblasting before plating or applying a matte coating post-plating.

Design and Pre-Production Process
The design phase began with careful art separation: vector artwork for the frame and high-resolution CMYK files for the printed scene. Pantone colors were assigned for the enamel sections, and print-safe colors were calibrated for accurate skin tones. The glitter and sandblast areas were annotated on production blueprints to ensure factory accuracy.

Production Workflow

1. Die-making and stamping – Steel molds were cut to create the raised outlines of the wreath and to shape both the frame and the inner pin.
2. Plating – Both components received gold plating, with selective masking for sandblasted textures.
3. Enamel filling and curing – Colored hard enamel was hand-filled into the recessed areas of the wreath, then kiln-cured for durability.
4. Polishing – The cured enamel was ground and polished flush to the metal surface for a smooth, glass-like finish.
5. Glitter application – Clear glitter enamel was applied to designated areas and re-cured to lock in the sparkle.
6. Printing – The central artwork was offset-printed onto the prepared metal surface of the inner pin.
7. Protective coating – A low-profile UV varnish was applied to seal the printed surface without adding a visible dome.
8. Pin-on-pin assembly – The printed insert was precisely aligned and fixed into the frame using mechanical posts.
9. Back post welding – Two posts were securely welded to the back of the assembled pin, followed by attachment of rubber clutches.

Quality Control and Finishing
Each pin underwent multiple inspections—checking enamel fill levels, glitter placement, print registration, surface polish, and structural stability. Special attention was given to the alignment of the pin-on-pin assembly, ensuring no visible gaps or misalignment.

Packaging
For retail presentation, the pins were mounted on custom backing cards and sealed in OPP bags. Bulk orders for events were packed with bubble wrap and carton dividers to prevent damage in transit.

Client Interaction Highlight
Our client remained engaged throughout the process, reviewing proof artwork, approving pre-production samples, and providing feedback on glitter density and texture contrast. “Our client said: ‘The layered construction and the glitter highlights exceeded our expectations—thank you for preserving the subtlety of the illustration while keeping a high-end finish.’”

FAQ
Q: What makes pin-on-pin construction worth the extra cost?
A: It allows different production methods to be used in one design, maximizing both texture and detail.
Q: How durable are glitter and translucent enamel areas?
A: When properly cured and sealed, they’re highly resistant to wear and color fading.
Q: Can the printed part be made water-resistant?
A: Yes—UV varnish or thin epoxy coating adds moisture resistance without compromising clarity.
Q: Will sandblast textures wear down over time?
A: With normal use, no. The texture is in the metal surface itself, so it’s as durable as the plating.
Q: Why use two posts instead of one?
A: Larger pins benefit from two posts for balance and to prevent rotation during wear.

Aurora and Philip: The Perfect Collectible Pin

Conclusion
The Aurora and Philip pin is a showcase of what happens when artistry meets precise manufacturing. Through the combination of hard enamel, pin-on-pin assembly, and carefully applied special effects, the final piece delivers tactile elegance and vivid storytelling. It stands as a prime example of how to blend traditional craftsmanship with modern printing for designs that are both collectible and wearable.