A Case Study of a Custom-Made Butterfly Pin

Hipins was approached by a client looking to design a premium-quality butterfly-shaped pin. The goal was to produce an elegant, colorful pin with high visual detail and sturdy structure. The project involved multiple stages: from design conception and mold creation to post-production finishing and client feedback. The entire process exemplifies our commitment to quality craftsmanship and responsive client communication.

1. Mold Process

The first step involved creating precision metal molds for the butterfly design. The client provided initial reference images, and our design team translated this into a vector-based mold design suitable for CNC engraving.

Each mold is machined from a solid block of hardened steel using CNC and EDM (Electrical Discharge Machining) to capture fine line details—essential for the intricate patterns on the butterfly wings.

Image Reference: The second image shows the engraved mold plates, with the butterfly mold located in the top left corner.

Key Steps:

• Digital design conversion
• CNC + EDM mold creation
• Polishing and testing for clean impressions

2. Blanks Done Process

Once the molds were ready, we began pressing zinc alloy (using the die-casting method) into the molds to form “blanks”—unpainted, uncolored pin bases. These pieces were then trimmed, deburred,and polished to ensure a clean shape.

Image Reference: The last image shows both the front and back of the finished blanks, displaying the detailed embossed surface and pin attachments.

Key Steps:

• Die-casting the butterfly shape
• Trimming and deburring
• Attaching pin hardware

3. Filling Colour Process

This butterfly pin design featured vibrant color fills. We used soft enamel coloring, hand-filled into the recessed areas of the pin. A dual-tone color scheme was applied: the first version had a light green and silver theme, while another had a blue, gold, and silver palette.

Each color is filled individually and then baked to harden the enamel. This part of the process demands patience and accuracy to ensure no color bleeding.

Image Reference:

• The first image shows pins with bright green wings post-color fill.
• The third and fourth images show progress of the blue-and-silver variant during and after the coloring stage.

Key Steps:

• Hand-filled soft enamel
• Multiple rounds for multi-color design
• Baking to set the colors

4. Wet Grinding Process

After color filling, the next step was wet grinding—a polishing method that smooths out the enamel so it sits flush with the metal edges, giving the pin a premium, smooth finish. This step also enhances the metallic outline of the pin.

The pins were submerged in water and polished on a rotating grinding wheel. This prevents overheating and preserves the enamel integrity.

Key Steps:

• Submerging the piece in water
• Polishing with wet-grinding tools
• Checking for surface flatness and finish

5. Communication Process

Throughout the project, communication between the client and our team was clear, transparent, and responsive. Key highlights of the communication process included:

• Initial Briefing: Understanding client requirements regarding shape, color preferences, pin back style, and intended use.
• Design Preview: Sharing 2D renderings and mockups before mold cutting.
• Production Updates: Frequent image updates were shared during blanking, coloring, and polishing stages.
• Approval Rounds: Each step was confirmed with the client before proceeding.

This back-and-forth ensured that the final product aligned precisely with the client’s expectations.

6. Post-Production and Client Feedback

Once all units were completed, the badges went through a final quality control check to inspect for any defects in enamel, metal edge quality, or pin alignment. The completed pins were individually packaged for shipping.

Client Feedback:
The client expressed high satisfaction with the final result, particularly appreciating:

• The clean, professional finishing
• Vivid color quality
• Quick turnaround time
• Responsiveness of the Hipins team

The success of this project has led to discussions about future designs and repeat orders.

FAQs About the Custom Badge Process

Q1: What materials are used for these pins?
We primarily use zinc alloy for its durability and ease of molding. For coloring, we use soft enamel paint, which allows for vibrant color applications.

Q2: Can I choose custom colors?
Yes, all enamel colors can be customized based on Pantone codes or reference images.

Q3: How long does the whole production process take?
From design approval to finished product, it typically takes 10–15 business days, depending on order size and design complexity.

Conclusion

This butterfly pin project is a testament to Hipins’ dedication to precision craftsmanship and collaborative customer service. From mold design to color fill and wet grinding, every detail was handled with care. The end result was a vibrant, detailed pin that exceeded the client’s expectations and reinforced our reputation for delivering top-quality custom work.