Cost
Challenge coins are moderately inexpensive to design and produce. There are two basic processes by which to manufacture: zinc-alloy castings or die struck bronze.
Zinc alloy castings offer the advantage of low cost. The quality is relatively good, but if carried as a pocket coin, the patina (finish) tends to wear off exposing the base metal. While a die struck bronze or brass coin is more expensive, the result renders a far superior product (numismatic quality).
As of 2010, coins manufactured in Asia typically cost between US$4.50 to US$12.00 per coin depending on production process and complexity of design, laser engraving, enamels, voids, etc. The dies must be sculpted by an artist and can range in cost from US$500 to US$900 depending on complexity. The cost of domestic manufacture can be two to three times this amount.
In order to be competitive, most North American companies offering challenge coins rely on having the product manufactured 'off-shore'. Many challenge coins are fabricated in South Korea, as the connection to the US military bases there is strong, and costs are cheaper than US made coins.
Read more about this topic: Challenge Coin
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