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Enamel Badges | Lapel Pins

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We are often asked how our badges are made, this video will help to explain just one of the many processes we use to produce badges.

Video is courtesy of “The Science Channel”

How Its Made

Manufacturing methods have hardly changed.  Enamel badges are still fired and polished by hand for the best finish.

1. From approval of the artwork, production of badges begins with a coloured drawing of actual size badge.

2. An outline of the badge artwork is cut in reverse on a plastic sheet at 5 times the actual size so that as much badge detail as possible is included.  

3. The badge outline is transferred via a reducing pantograph to the face of the actual soft metal die which is a piece of cylindrical steel and the appropriate areas are cut away.

4. The lines and letters that will appear on the badge are flush with the surface and the areas to contain the enamel are recessed.

5. The cut die is then heated in order to harden it.

6. Stamping is then done either on a drop stamp machine or hydraulic press.

7. Badges can then be cut to shape using a punch which has been cut to the required outline.

8. Pins or fastenings are soldered on to the backs of the badges.

9. Enamel which is glass in powdered form, is mixed with water into a paste and applied with a pen to sections of the badges, then heated to fuse with a flame gun.

10. Each enamel colour is applied separately to the badge to avoid them running into each other.

11. Between firings, badges are cleaned in acid to ensure the surface is free from scale.

12. After all enamelling is completed, the badges will have a lumpy appearance so they will need grinding carefully to create a flat and smooth surface.

13. The badges are liquified again for a moment to remove any scratch marks left by grinding.

14. Polishing then takes place on a circular electric mop to remove any grinding marks from the metal.

15. Finally, the badges are electro plated in either chromium or gilt, a process which leaves the coloured enamel untouched.

16. Following rigorous quality control, the badges are polybagged, boxed and shipped.

Manufacturing Process

of Enamel Badges