Table of Contents
- Project Overview
- Reorder Background and Project Scope
- Product Specifications
- Artwork Structure and Vertical Composition
- Color System and Material Strategy
- Manufacturing Process and UV Printing
- Backstamp, Attachments, and Structural Design
- Quality Control for Reorder Production
- Frequently Asked Questions
- Conclusion
Project Overview
This case study presents a 4-inch vertical hard enamel lapel pin developed as a reorder project for an existing design series. Compared with standard round or mid-size pins, this project required additional attention to structural stability, color control, and surface finishing due to its elongated format and dense illustration content.
The design features a single-character composition framed by an ornamental border, combining hard enamel, translucent sandblast enamel, pearlescent colors, and post-plating UV printing. The objective of this reorder was to maintain visual consistency with the original release while optimizing production accuracy and surface detail.
Reorder Background and Project Scope
Reorder Background and Project Scope
Unlike a first-run production, this project was a confirmed reorder, meaning the design language, color direction, and backstamp structure were already defined. However, reorder production does not eliminate complexity.
Key requirements for this reorder included:
Matching original color tones across multiple enamel types
Maintaining precise UV print alignment on plated metal
Adjusting attachment quantity to suit increased size and weight
Ensuring the backstamp layout remained consistent with previous editions
The total production quantity exceeded 65 pieces, placing it in a small-batch but high-detail manufacturing category.
Product Specifications
Product Specifications
Item Description
Product Type Hard Enamel Lapel Pin
Size 4 inches (vertical format)
Base Material Zinc alloy
Plating Gold
Process Hard enamel + UV printing
Enamel Types Solid, translucent sandblast, pearlescent
Attachment 4 rubber clutches
Finish Polished raised metal
Backstamp Custom text and logo
Packaging PVC bag + bubble bag
Production Type Reorder
The 4-inch format significantly increases both visual impact and production difficulty compared to standard pin sizes.
Artwork Structure and Vertical Composition
Artwork Structure and Vertical Composition
The artwork was designed specifically for a tall, vertical silhouette, allowing for a full-figure illustration surrounded by decorative floral and geometric elements. This layout demands strict control of line thickness and spacing, as even minor deviations become more noticeable on elongated designs.
Raised metal outlines define each color area, while circular decorative elements near the top frame provide visual balance and structural reinforcement. The overall composition guides the viewer’s eye from top to bottom, emphasizing narrative flow rather than symmetry.
Color System and Material Strategy
Color System and Material Strategy
This pin incorporates a complex color system combining multiple enamel and surface treatments:
Hard enamel for primary structural areas
Translucent sandblast enamel to introduce depth while revealing metal texture
Pearlescent enamel for soft highlights and visual variation
Clear glitter accents for subtle reflective detail
The gold-plated raised metal acts as both a decorative frame and a functional barrier, preventing color bleed during filling. Special attention was given to blue and purple tones to ensure consistency with the original release, as these colors are particularly sensitive to curing variations.
Manufacturing Process and UV Printing
Manufacturing Process and UV Printing
Production began with mold preparation using the original approved tooling, followed by stamping and surface refinement. After gold electroplating and polishing, hard enamel colors were hand-filled and kiln-cured to achieve a smooth, level surface.
UV printing was applied after plating and enamel curing, allowing for high-resolution detail on top of the finished surface. This method was used to reproduce fine textures, gradients, and line work that would not be achievable through enamel alone.
To enhance durability, a full circular clear gloss layer was applied over selected UV-printed areas, protecting the print while adding a subtle surface sheen.
Backstamp, Attachments, and Structural Design
Backstamp, Attachments, and Structural Design
The reverse side features a custom backstamp with centered text and branding elements. As this was a reorder, the backstamp layout remained unchanged to preserve edition continuity.
Due to the increased height and weight of the pin, four rubber clutches were used instead of the standard two. This configuration distributes stress evenly across the pin, reducing movement and improving wearing stability, particularly on thicker fabrics.
Quality Control for Reorder Production
Quality Control for Reorder Production
Reorder projects require a different quality control focus than first runs. In this case, inspections prioritized:
Color matching against previous production samples
UV print sharpness and alignment
Surface smoothness after multiple finishing steps
Attachment security and backstamp clarity
Each piece underwent visual inspection before packaging to ensure consistency across the batch.
Frequently Asked Questions
Frequently Asked Questions
Why use UV printing instead of traditional screen printing?
UV printing allows for higher resolution detail and precise placement on finished metal surfaces, making it ideal for complex illustrations.
Is UV printing durable for lapel pins?
Yes. When properly cured and protected with a clear layer, UV printing is suitable for collectible and display-focused pins.
Why are four rubber clutches necessary?
The 4-inch vertical format increases leverage and weight, requiring additional attachment points for stability.
Can this design be adapted to a smaller size?
Yes. However, some details may need to be simplified to maintain clarity at reduced dimensions.
Conclusion
Conclusion
This 4-inch vertical hard enamel lapel pin demonstrates how advanced production techniques such as UV printing can be combined with traditional enamel processes to achieve high-detail results at a larger scale. As a reorder project, it highlights the importance of consistency, precision, and controlled finishing.
By carefully managing color systems, surface treatments, and structural design, this project successfully delivers a premium collectible that remains faithful to the original release while meeting the demands of large-format pin manufacturing. It serves as a strong reference for future reorder and high-detail custom pin projects.