Overview
A client approached us with a playful yet refined design concept: a collection of custom enamel pins featuring expressive hippos. The goal was to create a five-piece series that captured humor and charm through diverse character expressions, while maintaining a high-end, collectible quality. The final result? A stunning collection of hard enamel pins, each with gold-plated edges, vibrant PMS-matched colors, and polished to a flawless gloss.
This project exemplified the full capabilities of our team—from design adaptation to high-precision die-striking, hard enamel craftsmanship, and meticulous quality control.
Pin Design Details
From the outset, the client emphasized a few critical points:
- A uniform size range (28.5mm–40mm) to keep the collection cohesive
- Hard enamel process to ensure a smooth, jewelry-like surface finish
- Gold metal plating across all pins for an upscale look
- Accurate Pantone color matching
- Detailed facial expressions and accessory effects
- A custom backstamp featuring their logo
- Retail-ready packaging with PVC + bubble wrap protection
The client aimed to market the pins both as fashion accessories and collectibles for young adults and lifestyle consumers.
Design Development
The client supplied high-resolution illustrations of five hippo characters, each conveying a different emotion or scenario:
- A calm hippo being gently patted
- A startled hippo with a large exclamation mark
- A front-facing hippo roaring dramatically
- A hippo smiling with a bird sitting atop its head
- A surprised hippo splashed by water
Each design was converted into vector outlines using Adobe Illustrator and underwent several optimization steps:
- Adjusting line thickness to ensure clean mold engraving
- Mapping PMS colors for enamel filling (e.g., PMS 7418, 504, 324)
- Identifying raised metal lines for plating
- Defining UV print areas for facial details like blush and highlights
- Integrating the backstamp for brand visibility
After three rounds of revisions, the client approved all proofs and the production plan.
Crafting Process
Our production team applied the hard enamel technique, known for producing a smooth, polished finish where enamel fills are flush with the surrounding metal. This process involves:
- Mold Creation & Die Striking
Using CNC engraving, each character’s outline and cutline was engraved into a high-strength steel mold. The designs were then struck into thick zinc alloy base blanks—ideal for capturing both detail and strength.
- Gold Plating
The entire surface was electroplated with a rich gold tone. This not only enhanced the visual appeal but also provided corrosion resistance.
- Enamel Filling
Individual enamel colors were hand-filled into recessed areas using PMS color guides. The hippo cheeks, for example, featured a warm blush tone (PMS 7418), while the water splash used a pearlescent aqua (PMS 324 + shimmer additive).
- Oven Curing
After filling, each pin was cured at high temperatures to “bake in” the color and hardness.
- Grinding & Polishing
Multiple polishing passes were used to remove excess enamel and reveal a perfectly flat surface. The result was a smooth and lustrous finish—indistinguishable from traditional cloisonné to the naked eye.
- UV Printing (Selective)
For added expression, fine lines and blush spots were UV printed, giving the faces more life and charm.
Quality Control
Each of the 400 pins underwent strict inspection. The breakdown was:
- 70 pcs: Patting hippo
- 80 pcs: Exclamation hippo
- 80 pcs: Roaring hippo
- 90 pcs: Smiling hippo with chick
- 80 pcs: Splashing hippo
QC Focus Areas:
- Color Accuracy vs PMS standard
- Surface Smoothness and polish consistency
- Backstamp Readability
- Clutch Attachment Test (pull resistance)
- Packaging Sealing & Labeling
The customer commented: “We were impressed by the high-quality finish and polished detailing. The color fill was flawless across all designs.”
Packaging & Delivery
To ensure retail readiness, each pin was:
- Individually bagged in PVC sleeves with bubble wrap
- Grouped by design into labeled inner packs
- Shipped with a digital QC report and sample photos
Thanks to precise planning and streamlined production, the entire batch was completed and shipped within 16 working days, including mold time and UV print setup.
Post-Production Support
Following the client’s initial launch, feedback from their community was overwhelmingly positive. Customers appreciated the sturdy feel and smooth texture of the pins, along with the vivid expressions and glossy finish. The splash effect pin, in particular, received standout reviews for its pearlescent detailing.
The client has since confirmed a follow-up project involving:
- Seasonal variants (e.g., winter accessories)
- Matching keychains and charms
- Eco-friendly card packaging with branding
Conclusion
This hippo enamel pin series highlights how charming design and industrial craftsmanship can unite in a product that resonates with customers emotionally and aesthetically. From the first vector line to the last polish, our team ensured that every detail met premium standards.
If you’re a designer, brand, or retailer seeking to turn your characters or stories into tactile, collectible items, we’re here to bring your vision to life—with guidance, transparency, and expertise at every step.