5 Tips for Making Cut-to-Shape Challenge Coins

5 Tips on Making Cut to Shape Challenge Coins

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While every challenge coin we make is truly unique, some really stand out amongst the rest. We’ve made almost every kind of coin imaginable, yet the creativity of our customers’ imaginations continues to astound us. Some of the coolest coins we’ve made to date happen to be cut-to-shape challenge coins. That is because nothing is more uniquely gratifying than a challenge coin in the shape of something near and dear to you.

Cut to shape challenge coins are a wonderful option to help make your coin stand out. Like most things however, there are some do’s and don’ts to making them Here are a few helpful tips to keep in mind when planning your design:

Challenge Coin Sizing

TIP #1 – Check the Dimensions

You should check your coin’s dimensions anyway, no matter what kind of coin it is. But it’s even more critical with cut-to-shape coins as they can have the illusion of looking larger than they actually are on the proof. For instance, these coins here are both 2”. However, one is 2” x 2” and the other is 2” by 0.75”. The largest diameters are the same, but the overall surface of the coin is significantly smaller. If you’d like to see exactly how big your coin will be, simply print off the proof we provided at 100%. If you need to increase the size, just let us know, and we’ll take care of that for you!   

TIP #2 – Consider Adding Some Functionality

If you’re going to make a custom cut-to-shape challenge coins, why not add some functionality? Using an existing cutout in the edge of the coin as a bottle opener is a great way to take your coin to the next level! Let us know If there is something you’d like to add specifically to your design. Our talented team of artists can help you find a way to incorporate what you want into your design.

TIP #3 – Save Some Cash by Reducing Cutouts

Sometimes, cutouts are essential for the design of a coin. Other times, they can be avoided. We want you to know what constitutes a cutout and how it can be avoided so that you can save money on your challenge coins! First, there are two kinds of cutouts: internal and external. Internal cutouts go right through the center and are surrounded on all sides by metal. External cutouts are when the coin’s edge goes into the design, like with this coin in the shape of the coin. Cutouts are relatively cheap, but since each one adds 10 cents to the cost of each coin, they can add up.

Cut to Shape Challenge Coins - Cut outs
Cut Out Examples for Cut to Shape Challenge Coins

TIP #4 – Avoid Making Parts Too Skinny

Plan your design so it doesn’t have any long, skinny pieces sticking out (such as a flag, sword, etc.). If it does, that’s fine, though. We’ll automatically take care of making the design manufacturable. We may have to beef up the thickness or add some extra recessed metal around it for support, but it’s nothing we can’t handle. While this is a rare occurrence, we thought we’d point it out anyway to help you better plan your design.

Cut to Shape Challenge Coin Minimum Specs

TIP #5 – Use Your Imagination

Finally, the most remarkable thing about custom challenge coins is that they’re, well… custom! We can bring your ideas to life and make anything imaginable. There are certain manufacturing limitations, but we can adjust your design for you and ensure they’re up to spec! If you’d like some inspiration, browse our website for ideas or check out our posts on Facebook and Instagram. You can also find more information on our Challenge Coin Upgrades page if you need more information on ways to customize your coin.

Custom Challenge Coins can be anything you imagine
Awarding a Challenge Coin

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Lone Star Challenge Coins

About Lone Star
Challenge Coins

We continually strive each day to make Lone Star Pins and Challenge coins the industry leader for all your promotional item needs. We do this by creating a customer centric environment. By putting our customers’ needs first, providing them with the industry’s best artwork, customer service and products, and by exceeding all expectations, we hope to create the ultimate customer experience.

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J and jarren
J and jarren
10 November 2023
My class spent well over $9,000 on our class coins. First issue, they didn't get them to us in a timely manner. We received them barely in time for graduation. Second, they sent us coins with a misspelled word (brave) as seen in the picture. Third issue, a lot of the spinners came broken, also as seen in the picture. When I reached out to the company, they claim sending replacement coins out at a later date is rectifying of this situation. Very empathetic to the situation at hand overall. Not very professional at all, terrible business practices and they definitely will not receive future business from me nor any recommendations either. Zero stars
M. Wong
M. Wong
27 October 2023
I found this company last year after a recommendation from a friend and I've ordered several times now. What keeps me coming back is the high level of customer service and responsiveness in the projects that have been created. The work product is also great and the quality of the coins, detail and just overall, I am very pleased with. This is my GO TO shop now for coins. Please check them out, you will not be disappointed! PS. Big shout to Corbin for his amazing guest service!
Stephen Ryan
Stephen Ryan
25 October 2023
This company is fantastic! I reached out to them to create a custom shaped coin with custom artwork that they had put together for me. The coins are a Veteran's Day thank you token for those who served at our company. We will definitely be returning for future orders. From start to finish, they were very open with communication, extremely fast to respond to concerns and questions, and lastly delivered something that blew us out of the water. Thank you so much!
Alejandra O'Connor
Alejandra O'Connor
25 October 2023
I ordered challenge coins on behalf of my government agency. Lone Star was easy to work with and did amazing things with the graphics I sent. They turned the artwork around quickly and each time it was better than what we had hoped for. We did have several back and forth messages to get the coin exactly as we wanted it. Our representative was so patient with us and had excellent customer service. We also got the coins in the mail quickly. Working with Lone Star was a wonderful experience end-to-end.
Italy Mair
Italy Mair
18 October 2023
Great service, great communication, and great products! Would definitely recommend them.
Rafael Moronta
Rafael Moronta
13 October 2023
Amazing artwork.. aside from the product what I loved most of our experience was the flexibility to create a coin that’s exceeds your own expectations. Thank you guys so much for making the process seamless and affordable!
5 October 2023
Absolutely fantastic company to work with. Communication was always quick, and the final product looked even better than the proof did. 10/10 would recommend!
26 September 2023
I engaged with Lone star challenge coins to make coins for my fiancé's celebration of life. I was pretty clueless about design, and they provided the perfect design. The coins arrived in time, and we were more than satisfied with the outcome. Their customer service was excellent as well. They guided me (held my hand) throughout the process, and were quick to respond. I cannot say enough about their product and company.
Debbie Avinger
Debbie Avinger
26 September 2023
We are so grateful for the work Lone Star Challenge Coins did for our nonprofit fundraising event! They worked with our budget and gave us medals with ribbons and challenge coins that were better than we expected.
Dan Kiser
Dan Kiser
22 September 2023
Corbin was very combative when I explained that the design provided was not at all reflective of the requests that I provided on the Inquiry form. Based on the customer service alone during that 1 phone call, I am not inclined to pursue any business with this company. EDIT: I spoke to the owner, Mike, and he helped rectify the situation and framed it as a learning opportunity for his team. This is a good reminder that people make mistakes but first impressions matter.
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