Overview

This case study details the creation of a custom hard enamel pin featuring a fox sitting among sunflowers. The client aimed to produce a high-quality, visually appealing pin with precise color details and a polished gold-plated finish. The project involved meticulous design work, careful material selection, and a structured production process to achieve a final product that met high-quality standards.

Pin Design Details

Details of this enamel pin included:

• Design Theme: A fox surrounded by two sunflowers, capturing a charming and elegant aesthetic.
• Material: Hard enamel for a durable and polished surface.
• Metal Plating: Gold-plated to enhance the warm color palette of the fox and flowers.
• Size: Approximately 44.5mm in height, ensuring a noticeable yet wearable size.
• Color Accuracy: Specific Pantone colors were provided for consistency and vibrancy.
• Attachment: Two rubber clutches for secure fastening to prevent loss or rotation.
• Packaging: PVC bags and bubble bags were used to protect the pins during transportation.
• Effect: Glitter

Some Crafting Processes

1. Design Approval & Digital Proofing

The initial stage involved translating the client’s digital illustration into a production-ready proof. The proof included:

• A colorized version with specific Pantone codes to guide the enamel filling process.
• A black-and-white version for mold-cutting reference, ensuring precision in metal shaping.

The client reviewed and approved the proof, confirming that the design elements, color choices, and overall layout met their expectations.

2. Mold Creation

• A 2.0mm-thick zinc alloy mold was crafted based on the design outline.
• Any small cutout areas were carefully considered to ensure they did not compromise the structural integrity of the pin.

3. Hard Enamel Filling

• These enamel pins were gold-plated, enhancing the overall warmth and sophistication of the design.
• Hard enamel colors were meticulously filled into recessed areas, ensuring that each color remained within its designated space.
• Enamel was baked at high temperatures to create a smooth, long-lasting finish.

4. Wet Grinding

Wet grinding can make the metal lines on the pins visible.

5. Polishing

The enamel pins were polished to a high gloss, removing any excess enamel and ensuring a flawless surface.

6. Plating

The base pins were gold-plated, enhancing the overall warmth and sophistication of the design.

7. Quality Control

• Quality control checks were conducted to inspect:
  • Color consistency and accuracy.
  • Metal plating quality (ensuring no scratches or tarnishing).
  • Smooth, bubble-free enamel application.

8. Attachment & Packaging

• Each pin was fitted with two rubber clutches to prevent movement when worn.
• The pins were packed in PVC bags with bubble wrap to minimize any risk of damage during transit.

Final Product & Client Feedback

Once production was complete, the client received the finished batch of pins and was highly satisfied with the results.

Client Feedback:

“The pins turned out beautifully! The gold plating gives them an elegant shine, and the enamel colors match our original design perfectly. The details, from the fox’s fur to the sunflower petals, are crisp and well-defined. The packaging was also well done, ensuring the pins arrived in perfect condition. We’re excited to work on future designs with this team!”

Challenges & Solutions

1. Ensuring Color Accuracy

• Challenge: The client provided a detailed color guide, and any deviation could affect the final appearance.
• Solution: By using precise Pantone-matched enamels, the team ensured each hue aligned perfectly with the original artwork.

2. Achieving Smooth Enamel Finish

• Challenge: Hard enamel must be polished carefully to create an even, smooth surface without affecting the metal edges.
• Solution: A multi-step polishing process was implemented, ensuring a flawless, glassy finish without dulling the gold plating.

3. Secure Attachment for Durability

• Challenge: The client requested dual rubber clutches to prevent the pin from rotating when worn.
• Solution: Two rubber clutches were attached for extra security, making sure the pin stays in place on clothing or accessories.

Conclusion

This project showcased the importance of precision, quality craftsmanship, and effective client collaboration in enamel pin production. By following a structured workflow—covering design proofing, metal stamping, enamel filling, and final polishing—the team successfully delivered a high-quality product that exceeded client expectations.

If you’re looking for custom enamel pin production with expert craftsmanship, contact us today to bring your designs to life!