Design

Production-Ready Vector Specs for Custom Pins and Badges

Spec line 1: Master file format and scale

The fastest way to lose 2 to 4 days in custom pin or badge sampling is to send artwork that looks complete but cannot be tooled directly. A factory needs closed vector paths, separated metal and color areas, a fixed final size, and unambiguous finish notes. If the only file is a PNG mockup or presentation slide, engineering has to redraw it, and every redraw adds approval risk.

For metal pins, brooches, badges, coins, and keychains, supply the master file as AI, EPS, PDF, CDR, or SVG with editable vector paths. Use 1:1 scale whenever possible. If the artwork is displayed at 200 percent or 500 percent for readability, state the final physical size separately in millimeters, for example: 32.0 mm W x 28.0 mm H. Include one visual reference JPG or PDF so engineering can compare the production paths against the buyer-approved look.

Raster images are acceptable only as references. They should not be treated as production files for enamel-separated metal goods. If raster is all you have, provide at least 600 dpi at final size for simple logos and 1200 dpi for small text, mascots, or line-heavy illustrations. Redrawing from raster usually adds 1 to 2 working days for simple pins and 2 to 4 working days for complex badges. If no vector reference exists, expect redraw tolerance to drift by about plus or minus 0.15 mm on small curves and corners.

A good master file should also note whether the design is intended for soft enamel, hard enamel, printed metal, die struck, or 3D cast production. That choice changes line width, channel depth, polishing allowance, and whether tiny details are manufacturable or should be simplified before quoting.

Spec line 2: Final size, outline, and bleed logic

The size line should define the maximum outside dimension of the finished metal item, not the artboard or image box. For example, a 30 mm pin means the widest outside metal edge is 30 mm, with height stated separately if the shape is not proportional. A clear format is: final size 30.0 mm W x 24.5 mm H, measured over plating, tolerance plus or minus 0.20 mm.

For die-struck and soft enamel pins, the outside metal border should usually be at least 0.30 mm, with 0.40 to 0.50 mm preferred for cleaner plating and fewer chipped edges. Hard enamel benefits from a stronger border, normally 0.45 mm or above, because polishing can soften very thin raised lines. For zinc alloy cast badges larger than 45 mm, outside edge tolerance is commonly plus or minus 0.30 mm. Stamped brass or iron under 35 mm can usually hold plus or minus 0.15 to 0.20 mm.

Bleed works differently from paper printing. Enamel does not bleed beyond a metal wall. Every color area must be trapped by raised metal unless the product is printed metal, UV print, offset print, or printed enamel under epoxy. If a buyer wants a borderless full-color gradient on a metal pin, the correct build is usually printed metal with epoxy, not traditional soft enamel.

The spec should also state whether internal cutouts are through-cut, partially cut, or decorative recesses only. A through-cut logo may need a minimum internal bridge of 0.40 mm to stay stable in tooling and handling, while a decorative recess can sometimes be narrower if it is not structural.

Dimension item	Typical target	Practical tolerance	Notes
Final outside size	20 to 35 mm for standard pins	±0.20 mm	Measure over plated edge, not artboard
Large cast badge size	45 to 70 mm	±0.30 mm	Use extra support for wide spans
Minimum outer border	0.30 mm	0.40 to 0.50 mm preferred	Hard enamel needs more support
Internal bridge	0.40 mm minimum	0.50 mm preferred	Prevents breakage in cut-through areas
Raster redraw drift	N/A	About ±0.15 mm on small details	Only relevant when vector is missing

Spec line 3: Layer naming and production separation

A production-ready file should separate information by function, not by visual convenience. At minimum, create layers for outline, raised metal, recessed enamel, print detail, cutouts, backstamp, attachment position, and reference notes. Do not leave hidden alternate logos, unused color tests, or old dimensions in the file. Factories may use the wrong path during tooling if inactive layers are not clearly removed.

For enamel products, the most important separation is raised metal versus recessed color. Raised metal becomes the mold ridge, typically 0.18 to 0.30 mm higher than soft enamel fill after plating, depending on item size and enamel depth. Hard enamel is filled above the metal walls and polished flush, so the raised line still controls color separation, but the final surface should be nearly level, with typical surface variation under 0.05 to 0.08 mm.

When a supplier receives complex buyer files, engineers usually convert them into a factory production drawing with numbered colors, metal finish notes, attachment marks, and tolerances. That drawing, not the decorative presentation mockup, should be the approval document before mold cutting. If your brand team wants to keep a polished mockup for internal review, keep it separate from the tool-ready vector file.

Layer name	What it should contain	Common mistake	Factory handling note
Cut line	Final outside shape and internal cutouts	Using a thick stroke instead of a closed path	Convert to a closed vector path before tooling
Raised metal	All metal borders and dividers	Metal lines mixed with black enamel art	Engineer separates by build, not by color
Enamel fill	Each recessed color area	Open paths and tiny islands below 0.25 mm	May be merged or removed for production
Print detail	Text, gradients, or fine art printed on top	Assumed to be enamel when too small	Requires print process and usually epoxy protection
Back side	Backstamp, pin posts, magnets, or clips	Attachment omitted or centered visually only	Position must be dimensioned from edges
Notes	Pantone, plating, thickness, packaging	Notes embedded in email only	Include in drawing to avoid version conflict

Spec line 4: Minimum strokes, gaps, islands, and text

The file should state minimum metal line width and minimum enamel channel width. For most soft enamel pins from 20 to 35 mm, use 0.25 mm absolute minimum raised metal line width, with 0.30 to 0.35 mm preferred. Minimum enamel fill channels should be 0.30 mm, but 0.40 mm is safer when the channel is long, curved, or near the outer edge.

Hard enamel is less forgiving because polishing can reduce definition. Specify 0.30 mm minimum raised metal and 0.35 to 0.40 mm minimum enamel channel for hard enamel, especially on gold, nickel, or black nickel plating. For die-cast zinc alloy keychains or large badges, 0.35 to 0.45 mm minimum metal is usually more realistic than pin-level detail because molten metal flow and finishing behave differently from stamped brass.

Small text deserves its own line in the spec. Recessed enamel text below 4.0 mm cap height is risky unless the font is bold and simple. Raised metal text can sometimes work at 2.5 to 3.0 mm cap height if strokes are at least 0.25 mm. If the text must be readable below 2.5 mm, use laser engraving, UV print, offset print, or a larger badge rather than forcing it into enamel.

Keep isolated enamel islands out of the file unless they are intentional and supported. A tiny floating island may trap air, wick color into an adjacent channel, or disappear during polishing. Serif fonts are also poor candidates below 4.0 mm cap height because the terminals break first.

• Set all strokes to outlined paths before sending; do not rely on software stroke weight.
• Remove isolated enamel islands smaller than 0.30 mm unless the factory confirms they can be filled.
• Avoid serif fonts under 4.0 mm cap height for enamel-separated text.
• Keep negative spaces inside letters, such as A, P, and R, above 0.30 mm where possible.
• Mark any detail that may be simplified as factory adjustable so approval does not stall over non-critical features.

Spec line 5: Color callouts, plating, and finish

Every enamel color should be numbered and tied to a Pantone Solid Coated reference, even if the brand guideline uses CMYK, RGB, or HEX. Enamel pigment is mixed to a physical color standard, so screen values are not enough. A realistic enamel color tolerance is usually within about one Pantone shade under D65 or daylight viewing, but transparent enamel, glitter enamel, and glow enamel can vary more because the base metal and additive load affect the final appearance.

The plating line should specify both color and target thickness. For promotional pins and keychains, common plating thickness is 3 to 5 microns for nickel, gold color, black nickel, or antique finishes. For higher-wear keychains, brooches, or bag charms, 5 to 8 microns is safer, especially on raised corners and jump rings where abrasion is concentrated. Very thick plating increases cost and may soften fine detail slightly, so it should be specified for use case, not simply requested as best quality.

Surface finish must be tied to the production method. Soft enamel has recessed color and raised metal. Hard enamel is polished flush. Antique plating requires recessed darkening and works best when relief depth is visible. Matte plating can reduce fingerprints but may show scratches faster than bright nickel, while black nickel gives strong contrast but can make dark enamel colors look muddy.

If the design uses translucent enamel or glitter, the spec should note the intended substrate. Transparent colors look different over brass, copper, silver, or black nickel. In practice, transparent blue over bright nickel reads lighter, while the same color over black nickel reads deeper and more saturated.

Spec item	Standard promo level	Higher-wear level	When not to choose it
Nickel plating	3 to 5 microns	5 to 8 microns	Avoid if nickel-free skin contact is required
Gold color plating	3 to 5 microns	5 to 8 microns with clear coat option	Avoid for heavy abrasion if color consistency is critical
Black nickel	3 to 5 microns	5 to 6 microns	Avoid with dark blue, black, or purple enamel unless contrast is tested
Soft enamel depth	0.18 to 0.30 mm recessed	Deeper recess on larger badges if design allows	Avoid for designs needing a flat luxury surface
Hard enamel polish	Flush within about 0.05 to 0.08 mm	Extra polish control on premium badges	Avoid for tiny detailed art that will blur during polishing

Spec line 6: Attachment position, back details, and orientation

The back side should be drawn, not assumed. For lapel pins, a single post is common on items under 25 mm; two posts are safer for 30 mm and above, wide horizontal shapes, or any badge that must not rotate. Standard pin post diameter is commonly around 1.0 to 1.2 mm, with post length about 7 to 8 mm, paired with butterfly clutch or rubber clutch depending on the order requirement.

For brooches and larger badges, specify brooch bar length and position. A 38 to 45 mm badge often uses a 25 to 30 mm brooch bar, while larger 50 to 65 mm pieces may need a 35 to 45 mm bar or dual attachments to prevent sagging. If the badge is intended for thin shirts, heavy zinc alloy may damage fabric; stamped iron or brass at 1.2 to 1.5 mm thickness can be more wearable than a thick cast body.

Backstamp artwork should state raised, recessed, or laser-engraved. Raised or recessed backstamps need minimum strokes of about 0.25 to 0.30 mm and are usually built into the mold, so changing them after sampling can require mold modification. Laser-engraved serial numbers or batch codes are flexible, but the engraved area should be flat and at least 8 x 4 mm for short codes or 12 x 12 mm for scannable QR codes.

Orientation matters as much as geometry. If a left-facing and right-facing version will share the same artwork family, label them clearly in the file name and in the notes. A reversed backstamp, mirrored post position, or upside-down clasp can turn a workable sample into a rejected one even when the front face is correct.

Spec line 7: Sampling, inspection, and acceptance lines

The artwork spec should define what the factory sample is proving. A pre-production sample checks size, plating color, enamel fill, attachment strength, surface appearance, and packaging fit, not only the logo shape. Typical sample time for enamel pins and badges is 7 to 10 working days after artwork approval; complex 3D relief, moving parts, glitter, transparent enamel, or printed epoxy designs may need 10 to 15 working days.

Mass production lead time after sample approval is commonly 10 to 18 working days for 100 to 1,000 pieces, 15 to 25 working days for 1,000 to 5,000 pieces, and 22 to 35 working days for larger or multi-SKU orders. Production can be tighter when tooling, plating, enamel, and packing are handled in-house, but rush schedules still depend on mold queue, plating color, curing time, and final inspection. Air freight should be planned separately, usually 3 to 8 days depending on destination and customs clearance.

Inspection criteria should be written before production. For general promotional metal goods, many buyers use AQL 2.5 for major defects and AQL 4.0 for minor defects, with critical defects not accepted. Major defects include wrong plating, wrong attachment, missing color, unreadable required text, sharp burrs, broken posts, and severe scratches visible at normal viewing distance. Minor defects include tiny dust points, slight enamel waviness, or very small plating marks outside the logo focal area.

For higher-value retail items, some buyers tighten to AQL 1.5 for majors and 2.5 for minors, especially when the product is sold through e-commerce or gift retail and returns are costly. If the order includes children’s products or safety-critical attachments, define the pull test, packaging seal, and warning label requirements before production begins.

• Confirm final size tolerance: plus or minus 0.20 mm for small stamped pins, plus or minus 0.30 mm for larger cast items unless otherwise agreed.
• Confirm color tolerance: visual match to approved sample under daylight or D65 lighting, not to a phone screen.
• Confirm attachment pull check: posts and brooch bars should not detach under normal handling; request a defined pull test if the item is safety-critical.
• Confirm plating acceptance: no exposed base metal, no peeling, no heavy pitting on the front surface.
• Confirm packing: each item in an individual polybag, paper card, backing card, or gift box as specified before carton packing.

Spec line 8: Price, MOQ, and what to send next

A vector spec sheet also helps commercial comparison because it removes guesswork from quotes. For simple soft enamel pins around 25 to 30 mm, typical FOB China pricing may range from about USD 0.35 to 0.90 per piece at 500 to 1,000 pieces, excluding unusual packaging and depending on metal, colors, plating, and attachment. Hard enamel of the same size often ranges from about USD 0.55 to 1.30 per piece because of additional filling and polishing steps. Tooling is commonly separate, often around USD 35 to 90 for simple 2D pin molds and higher for large, 3D, or multi-part products.

MOQ depends on process and cost structure. For standard enamel pins, 100 pieces per design is often workable, but 300 to 500 pieces gives better unit cost because mold, setup, and color mixing are spread over more pieces. For custom cast keychains, large brooches, printed epoxy badges, or multi-attachment products, 300 pieces is a more practical starting point. For patches and lanyards, MOQ logic is different because fabric setup and printing meters drive cost.

Do not over-specify beyond the product’s purpose. A one-day event giveaway does not need the same plating thickness, individual gift box, and inspection plan as a retail collectible pin. But do specify the features that affect failure: vector paths, size, minimum lines, Pantone colors, plating thickness, attachment position, sample approval standard, AQL level, and packing method.

What to do next: send your supplier one production-ready vector file, one visual mockup, and one written spec sheet using the lines above. Ask the factory to return a production drawing with any simplifications marked before mold cutting. If you want a review, include final quantity, target delivery date, destination country, intended use, and whether the item is for retail sale, staff uniform, event giveaway, or child-facing promotion; those details change the safest material, attachment, and QC plan.

Have a project? Send your artwork and target quantity and we’ll reply with a detailed quotation within 12 working hours.