How It's Made
MOLD
Molds are created by uploading the digital proof file of the outline to a machine that cuts the design into steel. This mold is then tempered to withstand the creation of the embryos or 'blanks' as they are sometimes called.
EMBRYO
Die Cast: The embryos are created by filling the mold with molten alloy under high pressure, after the metal cools, the embryo is then removed from the machine. Embryos are created one at a time but on average 25 can be made in 10 minutes. Embryos are still extremely hot once they’re taken out of the machine which can distort the shape. After they have cooled if there is any excess or rough edges, they are filed to ensure a smooth shape.
COLOR FILLING
After embryos have passed quality checks, a blue layer of paint is sprayed over the back and edges. This paint will make it easier to remove any stray enamel that sticks to these sides. All embryos are placed in the oven to bake before the colour filling process begins.
Every colour on a pin is mixed by hand based on the selected Pantone colour from the proof. These colours are then applied with a syringe and needle tubing one at a time. After one colour is applied, all pins must be baked for 40 minutes at 194° degrees to cure the enamel. This process is then repeated until all colours are on the pin and cured.
STONING & POLISHING
All pins are then moved to the stoning machine which flattens the enamel on the surface of the pin, after the enamel is flat, the pins are polished. Each pin is stoned and polished by hand, one at a time.
PLATING
The plating process is what allows different metal colours to be selected to enhance the design; including, silver, gold, black nickel, rose gold, copper, rainbow and increasingly 'ombre' or single colours
The pins are attached to metal racks. Once mounted, the racks are placed on electrodes within a chemical solution. This allows a electric charge to pass through the pins. Some of the solutions are to clean the base metal. Others add specific colours to the metal. Each step of the process is timed to ensure consistency of colour.
The pins are attached to metal racks. Once mounted, the racks are placed on electrodes within a chemical solution. This allows a electric charge to pass through the pins. Some of the solutions are to clean the base metal. Others add specific colours to the metal. Each step of the process is timed to ensure consistency of colour.
During the electroplate process, every pin is electroplated nickel first. Nickel is another name for 'silver'. Although it's not exactly accurate because it is not actual silver being applied to the pins. (It's more like chrome to be precise). Once the pins are electroplated nickel you can then change the colour to bronze or gold. The electric charge causes the ions from the electroplating solution (bronze, nickel or gold) to attach to the pin base.
Electroplating is a multi-step chemical bath process that changes the colour of the base metal from zinc's dull grey to the variety of colour options available.
PRINTING
Screen print: First a screen print must be created for each individual colour that will be printed over the pin, the print screen is then aligned either by hand or machine and placed over the pin where paint is swiped across leaving an impression in that colour, Pins are printed one by one and a single colour at a time. A curing agent is applied over the areas that require printing, this ensures that the paint dries fast and does not remove easily.
UV Print: rather than done by hand swiping the pigment across the pin to add details, the print is completed by machine allowing multiple to be done at once- often used for gradient effects or where screen printing simply cannot handle the level of detail in a design.
After all colours have been printed on the pins, all pins are baked for about 30 minutes to ensure that all the paint has dried.
Et Voila the pin is done!
After this step, all pins are moved to the final quality control and packed up to be sent to me in Australia.