At Hipins, we thrive on bringing the most intricate visions to life. This case study showcases a recently completed project for a valued repeat customer—a striking dual-variant custom pin set with refined details, advanced finishes, and a highly efficient production cycle.

Without requiring any sampling, the client trusted us to move directly into mass production, based solely on artwork approval. The two versions—referred to as Variant A and Variant B—share the same structure but differ in color schemes and quantities. This blog will walk you through the project from design specs and communication flow to final delivery and client satisfaction.

1. Design and Production Specifications

This pin design features a dynamic and elegant witch illustration with flowing hair, a detailed dress, and fine outlines that required both artistic sensitivity and precise engineering.

🧩 Structure Overview:

• Material: Hard enamel on zinc alloy base
• Plating: Gold
• Attachment: Dual rubber clutches
• Backstamp: Custom logo with Witching Studio branding
• Size: Approximately 4 inches in height
• Variants:
  • Variant A: 140 pcs
  • Variant B: 30 pcs

🎨 Color & Effects:Both A and B versions used a common mold but diverged in surface finish and color combinations. Key effects included:

• Pearlescent gradient in specific enamel zones (non-mixed layering)
• Transparent sandblasting applied to selected recessed areas
• Silkscreen printing for fine line detailing and visual enhancement
• Partial glitter fills for visual balance (particularly in Variant A)

We worked with over 15 individual Pantone color codes across both variants, requiring detailed mapping to ensure clarity and vibrancy after baking.

2. Communication Process

What made this project truly efficient was the streamlined communication between our design team and the client.

🗂️ Step-by-step breakdown:

• Artwork Confirmation:
  The client submitted a finalized design file with specified effects, color codes, and desired placements for glitter, sandblast, and gradients. This was especially helpful in aligning expectations early on.
• Effect Feasibility Check:
  Our engineering team reviewed the request to apply a pearlescent gradient without blending colors. We confirmed the technical feasibility and suggested slight layering adjustments to ensure smooth transitions and reduce overflows.
• Mock Visualization & Feedback:
  Even without a physical sample, we provided enhanced mockups showing how pearl gradients and transparent sandblast zones would appear after baking and polishing.
  → The client approved these visualizations immediately, citing full confidence in our process due to previous orders.
• Backside Layout Approval:
  We aligned the backstamp positioning and ensured rubber clutch holes did not interfere with the logo or structural support zones.

This high-efficiency communication model allowed us to complete all confirmations within 48 hours.

3. Production Execution.

🔩 Mold Manufacturing:

We used CNC engraving to create a shared mold capable of capturing the ultra-fine lines in the hair, dress folds, and hand pose. To protect design integrity under mass production, we implemented a multi-level etching strategy that separated deep-fill areas (for glitter or sandblast) from shallow decorative regions.

🎨 Coloring and Effects Application:

• Pearl Gradient:
  We used our step-feed non-mix method to apply the pearlescent gradient. It’s a technique where pigment is laid down in segments using precision droppers, avoiding any swirl or overlap. Baking followed immediately to lock in the particles.
• Transparent Sandblast:
  Applied to recessed areas using clear enamel infused with matte agents and micro glass powder. Once hardened, it formed a frosted window effect that enhanced depth without overpowering surrounding colors.
• Silkscreen and Glitter Details:
  Silkscreen outlines were manually aligned and screen-printed in high-contrast black for clarity. On Variant A, micro-glitter was embedded in select dress areas to mimic magical sparkles.

🧽 Polishing and QC:

• Manual high-gloss polishing was conducted on raised metal outlines.
• Each pin underwent 3-layer QC, focusing on color separation, glitter dispersion, and logo clarity.

4. Post-Production and Client Feedback

The batch was completed ahead of schedule, with careful packaging using individual PVC bags and bubble protection. Final shipping included a full inventory sheet, backstamp proofs, and production notes.

Upon receiving the products, the client shared the following feedback:

“This is the best pin batch I’ve ever produced. The pearl effects are exactly how I imagined, and the transparent sections are beautiful in natural light. Zero defects. Thank you for making this flawless!”

They also reported that most of the Variant A pins sold out within the first 48 hours of launch—solid proof that great production turns into commercial success.

What Makes This Pin Project Stand Out?

• No Sampling Needed: Complete trust enabled direct production, saving time and cost.
• Complex Craft Integration: Successfully combined multiple advanced techniques on one shared mold.
• Visual Impact: The balance between glitter, pearl, and transparency made the design pop.
• Repeat Client Relationship: Years of cooperation led to effortless execution and mutual growth.

FAQs

Q1: Can I order two pin variants using one mold?
Yes. As long as the structural design remains the same, color variations can be handled on the same mold.

Q2: What is a pearl gradient effect?
It’s a color fill using pearlescent powder that gradually changes tone without blending. We use step-feed techniques for clarity.

Q3: How is transparent sandblast created?
It involves applying matte-treated clear enamel to recessed zones, forming a soft, frosted texture beneath the surface.