Can I Make Challenge Coins With a Laser Engraver?
Ever held a challenge coin and thought, “Could I make one of these myself?” Short answer: yes—with a laser engraver, you can craft detailed, custom coins. From history to design tips (and even the 5 Best Lasers for Challenge Coins), this guide shows how to bring your coins to life.
Feasibility of Laser-Engraved Challenge Coins
Challenge coins have always carried weight. They’re not just metal discs — they represent belonging, achievement, and history. The good news? Yes, you can absolutely make them with a laser engraver, and the results can be just as striking as traditional minting.
What Makes a Coin a “Challenge Coin”?
Military and commemorative standards
Challenge coins started in the military, where they were used to prove membership and build camaraderie. Over time, the idea spread to police forces, fire departments, corporations, and even hobby groups. What they all share is meaning — whether it’s a unit emblem, a team logo, or a mark of recognition.
Materials and designs that work best
The classics are brass, copper, and aluminum, though stainless steel and zinc alloys are common too. These metals engrave beautifully with fiber lasers, producing clean, permanent details. Designs often feature crests, mottos, or symbolic artwork — and with a laser, you can push into finer details like micro-text or even QR codes.
How Laser Engraving vs Traditional Strike Production Differs
Cost comparison: tooling vs laser setup
Traditional coins require dies or molds. These are expensive to produce, which makes sense for mass production but not for small batches. With lasers, there’s no tooling — once you have the machine, you can engrave one coin or a hundred without paying for new molds.
Design flexibility and iteration speed
Think of it like the difference between film and digital cameras. Traditional striking locks in the design until you make a new die. With lasers, you can tweak the artwork in your software and test it instantly. This opens the door to faster prototypes, one-off designs, and more creativity.
Equipment Needed for Coin Production
Laser Type and Power Requirements
Fiber vs diode vs UV lasers
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Fiber lasers are the go-to for metals. They cut cleanly into brass, steel, and aluminum.
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Diode lasers are affordable, but they’re underpowered for coins unless you use marking sprays.
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UV lasers excel at plastics, glass, or coated items, but they’re not ideal for raw metal coins.
Recommended wattage for metal engraving
For coins, you’ll want a 30W–60W fiber laser. Lower wattage (20W) can work for surface etching, but if you want deeper relief or faster runs, more power saves you both time and headaches.
Fixturing and Rotary Attachments for Coins
Coins are small, round, and slippery. Without a proper fixture or jig, they’ll move under the beam. A rotary attachment is also handy if you want to engrave edges or 3D surfaces, keeping everything aligned while the coin spins smoothly in place.
Cost Considerations for Custom Challenge Coins
Average Pricing per Coin
Custom factors—size, finish, volume
A simple coin might cost $5–$10 each, while larger pieces with color fill, plating, or specialty finishes can run $15–$25 each. Order volume matters too — bulk runs slash costs, while one-off custom coins stay on the higher end.
DIY vs Manufacturer Pricing
Buying your own fiber laser is an upfront investment — typically $3,000 to $8,000+. But once it’s in your shop, your per-coin cost drops dramatically. If you outsource to a manufacturer, you skip the equipment costs but pay more per coin and lose the flexibility of last-minute design tweaks.
Legal & Ownership Questions
Can Civilians Own Challenge Coins?
Absolutely. While they began in the military, today you’ll find challenge coins in law enforcement, corporate events, charities, and even weddings. Collectors, businesses, and hobbyists all design their own coins without issue.
Compliance and Trademark Issues
The only legal wrinkle is intellectual property. Military insignias, company logos, or copyrighted artwork can’t be used without permission. If you’re creating coins for resale or formal recognition, always make sure you have the right to use the designs.
Final Thoughts
Laser engraving has opened up challenge coins to anyone with the right tools and creativity. Whether you’re commemorating a milestone, honoring a team, or just experimenting with design, lasers make it possible to create coins that are unique, meaningful, and durable.
The tradition remains the same — but the tools have changed.
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