1. Overview
Oversized enamel pins and multi-layer constructions have rapidly transformed the custom pin industry. Once considered niche specialty formats, they are now embraced by artists, brands, and collectors seeking richer storytelling and striking visual presence. With larger surfaces, deeper relief options, and more dynamic structural possibilities, these designs offer what small standard pins cannot: a canvas capable of holding emotion, scene-building, and expressive detail.
This case study explores a recent project from one of our valued clients, who sought an oversized, layered enamel pin series that would function as the centerpiece of their limited-edition art release. Their goal wasn’t simply to scale up the artwork—it was to bring narrative and dimensionality to life, while maintaining durability and premium craftsmanship.
The project showcases how thoughtful engineering, refined enamel processes, and close collaboration can produce a design that feels more like collectible art than a simple accessory.
2. Client Requirements
The client approached us with a clear creative ambition: a visually commanding, multi-layer enamel pin that tells a story at first glance. Their request included:
- A large size between 55–65 mm, much bigger than typical pins.
- A layered structure involving at least three metal plates.
- High-contrast metal finishes to emphasize depth.
- Smooth, polished surfaces with hard enamel consistency.
- Backing stability for display and wearability.
- Packaging suitable for limited-edition merchandising.
The client emphasized that these pins would not be everyday accessories; they would be art pieces intended for collectors. “We want people to feel the depth of the design,” the client said. “The layered structure should look like a miniature art relief.”
This direction aligned perfectly with the rising market trend favoring bold visuals and enhanced dimensional storytelling.
To guide the client’s planning, we referred them to internal resources listed in our size reference guide, enamel process overview, and metal plating explanation page, helping them understand how dimensions, materials, and finishes would affect cost, appearance, and structural stability.
3. Crafting Process
Oversized and layered pins require more than simply enlarging a typical design. Each stage—from mold engineering to enamel filling—must be calibrated for precision.
Concept to Technical Blueprint
The client provided an initial illustration featuring a central character, surrounding environmental elements, and a decorative border. Our design team translated the imagery into a technical drawing with separated layers:
- Layer 1 (Base Plate): Background scenery, border elements, and cutout windows.
- Layer 2: Character silhouette with raised outlines.
- Layer 3: Foreground elements, including metallic accents and color-block details.
Multi-level construction meant multiple molds, each requiring accurate line separation to prevent misalignment during assembly.
Engineering Considerations
Large pins can warp if weight distribution isn’t balanced. To counter this, we recommended:
- Zinc alloy for the base plate to provide stability with reduced weight.
- Brass for the upper layers to preserve crisp detail.
- Two back posts to prevent rotation during wear.
Layered enamel pins rely heavily on careful polishing, as uneven surfaces can cause color reflections to appear inconsistent. We applied a multi-stage polishing technique described in the manufacturing training materials (from the technical file you uploaded ), ensuring high gloss without erasing fine lines.
Metal Finishes
To enhance contrast between layers, we recommended:
- Black nickel plating for the base layer
- High-polish gold for accent lines
- Misty silver for the foreground details
This multi-finish approach allowed light to catch the pin differently from each angle, maximizing the layered effect.
4. Client Interaction Highlights
Throughout development, communication with the client was consistent and collaborative. They valued transparency and visual previews at each phase:
Design Adjustments
When reviewing early diagrams, the client noted:
“We want the character to feel like it’s stepping out from the background. Could the depth be more dramatic?”
We adjusted the layer separation by increasing the metal relief height on the top plate. This small change significantly amplified dimensionality.
Color Matching
The client supplied their preferred Pantone palette. We prepared enamel test swatches and compared them under natural and studio lighting, as enamel color perception shifts depending on surface area and lighting temperature—especially in oversized designs.
Prototyping Feedback
Upon receiving the prototype, the client shared:
“The layering is stunning. Seeing it in person makes such a difference. The weight feels substantial without being too heavy.”
Their feedback guided us through final refinements, including polishing brightness and the subtle rounding of exposed edges to enhance comfort.
5. Production Workflow
Once the design and prototype were approved, full production began. Oversized and layered pins follow a more complex workflow than standard enamel pins.
1. Mold Creation
Each layer required its own mold, etched with deep relief lines to achieve crisp detail after casting. CNC engraving ensured the dimensional accuracy essential for multi-plate alignment.
2. Casting & Forming
- Base layer: cast in zinc alloy for shape stability.
- Secondary plates: cast in brass for sharp detail retention.
Excess metal was trimmed, and each plate was individually polished to remove casting texture.
3. Assembly
The layered structure was assembled with micro-welding techniques. This avoids visible seams and ensures the plates remain securely bonded during wear.
4. Enamel Application
Hard enamel color was added manually using syringes for precise placement. Each color required:
- Application
- Baking
- Sanding
- Final polishing
This process is also described in your training document as part of the hard enamel finishing workflow (referenced in the uploaded technical file ).
5. Plating
After assembly, the piece was plated as a whole to ensure even finishes across all levels. Layered designs require careful masking to preserve contrast between plating types.
6. Inspection
Because of the size and complexity, inspection was particularly rigorous, checking:
- Alignment of metal layers
- Enamel flatness
- Micro-scratches on polished surfaces
- Edge comfort
- Back post stability
The consistency rate exceeded expectations for such complex pins.
6. Post-Production Details
Backing & Stability
Given the pin’s size, we installed dual rubber clutch posts for comfort and stability. The client also opted for a limited run of magnetic backings for framed display editions.
Packaging
Oversized pins require reinforced presentation. The final packaging included:
- A custom-sized backing card
- A protective foam layer
- A clear display window
- A collector-edition label sticker
The packaging elevated the pin from merchandise to a collectible art object.
Quality Preservation
We recommended:
- Avoiding long-term direct sunlight
- Storing in a dust-free display case
- Handling edges to prevent fingerprints on high-polish plating
This is especially important for multi-layer plated surfaces, as each finish can reflect oils differently.
7. Client Feedback
The project was exceptionally well received. The client shared glowing feedback:
“This is exactly what we envisioned—bold, dimensional, and expressive. The layered construction gives the piece a unique presence, and the enamel work exceeded all expectations.”
They specifically highlighted:
- Standout visual depth
- High polish quality
- Accurate Pantone matching
- Smooth, comfortable edges
- Packaging that felt premium and gift-ready
The oversized pin became the centerpiece of their release, selling out quickly and receiving enthusiastic responses from collectors.
8. Call-to-Action
If you’re planning an oversized or layered enamel pin project, our team can guide you from concept to polished product. Whether you’re building a collectible series, launching limited merchandise, or looking to create a statement piece, we’re here to support every stage—from design translation to engineering, plating, and packaging.
Reach out anytime to begin your custom pin journey. We’ll help you transform your artwork into a premium enamel piece that captures attention and tells your story with depth and clarity.
9. FAQ
What makes oversized enamel pins more visually impactful?
Their larger surface area allows more intricate detailing, bolder line work, and layered structures that create dramatic depth and storytelling potential.
Are layered enamel pins heavier than standard pins?
Yes—multi-plate designs naturally carry more weight. We offset this by selecting appropriate alloys and using two back posts for stability.
Can oversized pins include moving elements?
Absolutely. Hinges, sliders, and spinning components are compatible with layered designs.
Which enamel type works best for oversized pins?
Hard enamel is preferred for a smooth, refined finish. However, soft enamel or printed accents can be added for textured effects or gradients.
Do multi-layer pins require special packaging?
They benefit significantly from reinforced packaging to protect edges and preserve presentation value—especially for collector editions.
Is production longer for oversized or layered pins?
Yes. Multiple molds, layered assembly, and detailed enamel finishing extend production timelines. Planning ahead ensures optimal results.
What plating options work best for layered designs?
Contrasting finishes—such as black nickel against polished gold—enhance depth and highlight the layered structure.