This case study showcases a bespoke pin-on-pin enamel badge project designed for a high-end collectible line. With a dual-layered structure, fine UV detailing, and limited edition numbering, this 4.5-inch piece blends craftsmanship with creativity, representing an advanced level of custom enamel pin production.
Overview of the Design
The pin design features a stylized “Sugar Skull Cat Girl” motif, visually centered around a colorful and detailed female character with fox ears, floral crown, and sugar skull face paint. The client provided layered artwork, which was then broken down into a two-piece construction:
- Top Layer: 3.5mm thick raised matte gold metal frame with ornamental engraving.
- Bottom Layer: 3mm base layer housing the full-color printed and enameled artwork.
The artwork is rich in gradient tones, glitter finishes, and uses translucent and pearlescent enamel fills to enhance depth and contrast. The visual complexity necessitated both hard enamel processing and UV printing, particularly for elements like the eyes, hair, and background effects.
Crafting Process
- Digital Separation & Mold Making:
The original artwork was digitally layered to identify cutouts, frame borders, and recessed areas. Molds for both the top and bottom layers were created with high-precision CNC engraving.
- Base Metal Selection & Die Striking:
Zinc alloy was chosen for its compatibility with 3D relief and large-format pins. Both parts were die-struck, with the frame receiving special attention for maintaining clean ornamental cuts.
- Plating:
A matte gold plating was applied to both layers. Matte finish enhances the contrast with the vivid printed details and provides a subtle luxury texture.
- Hard Enamel Filling:
Over 30 PMS color-matched enamel shades were used, including black, rose, and multiple shades of pink. The gradient pearl tones were applied carefully to areas such as the hair and roses, requiring hand-filling and baking for each color.
- UV Printing:
For areas with complex detailing (such as the facial features and highlights), UV printing was used. This technique allowed the reproduction of high-resolution gradients and soft shadows not achievable with enamel alone.
- Assembly & Backstamp:
The top layer was mounted onto the bottom with pin-on-pin mechanics using four back posts with rubber clutches. A laser-engraved serial number from LE 1/25 to LE 25/25 was applied to the reverse, along with the client’s custom logo and the “Lavender Pins” brand mark.
- Packaging:
Each pin was packed in a protective PVC bag with bubble wrapping to ensure safe delivery to collectors.
Frequently Asked Questions (FAQ)
Q: Why combine hard enamel with UV printing?
A: UV printing allows full-color imagery with gradients and soft details, while hard enamel adds durability and a premium tactile finish. The combination ensures both aesthetic and structural quality.
Q: What is pin-on-pin construction?
A: Pin-on-pin means two separate metal parts are stacked and joined. It adds depth and a 3D effect, ideal for complex designs or layered storytelling.
Q: How do you apply translucent or glitter effects?
A: We use specific enamel formulations like translucent PMS tones or glitter enamel, which are filled and baked manually, layer by layer.
Q: What’s the standard thickness for high-end pins?
A: This project used a 3.5mm frame over a 3mm base. While most pins are under 2mm thick, luxury designs often range from 3–5mm for structural integrity and visual weight.
Q: Can I order similar pins in lower quantities?
A: Yes, but expect higher unit pricing. This project was done with a MOQ of 25 pieces. We recommend ordering 50+ for better pricing per unit.
Conclusion
This limited edition “Sugar Skull Cat Girl” pin is a testament to what’s possible when artistry meets precision manufacturing. By combining pin-on-pin construction, hard enamel craftsmanship, and UV printing technologies, the result is not just a badge but a collectible centerpiece.
Whether you’re an independent artist, a brand manager, or a collector seeking premium enamel pins, this case demonstrates how thoughtful design and quality materials elevate the final product. For brands looking to make a statement through custom art enamel pins, this dual-layer process offers a versatile and luxurious solution.
Need help with your next pin-on-pin or mixed-media enamel badge? Contact our team to bring your vision to life.