Custom Designed Challenge Coins

Aviator Gear designs custom challenge coins for military flying squadrons, aviation units, MAJCOMs, NATO groups, corporate teams, and professional organizations. We specialize in custom military challenge coins, high-quality unit challenge coins, and engraved commemorative coins that represent your mission, history, and identity.

Custom-designed challenge coins start at $3.00 and up. Final pricing depends on size, quantity, design complexity, plating options, 3D sculpting, edging styles, and any functional features such as bottle openers.

The main drivers of the price for your custom coin will be size, quantity, and any extra features, such as edging, engraving, or consecutive numbering. We always provide a custom quote for our coin designs.

Your artwork and design consultation is always free with us. Our die (mold) charges are very low, ranging from $125.00 - $200.00, depending on the size and design features, which includes both sides of the coin. This die charge is non-refundable and only applies to your initial purchase.

The die charge only applies to your initial purchase, and we will keep your mold ready for reorders.

We provide free artwork and professional design consultation. Die charges are kept low, and there are no fees for standard revisions during the design process.

Yes. You can design your own challenge coin online while working directly with our experienced design team. We provide free artwork, professional design consultation, and unlimited revisions to ensure your custom challenge coin matches your exact vision before production begins.

Yes. We offer unlimited design revisions at no additional cost. Our goal is to refine your custom military challenge coin until every detail, from insignia to text placement, meets your expectations.

98% of our clients approve their coin order for production, based on the final approved artwork proof. We can create a physical sample of your coin, prior to full production; however, we require a non-refundable payment of the die charge before we create your sample coins. Once that die has been created, it cannot be modified. Any changes to the coin design, once you receive the sample coin, will require a new mold and another die charge. This is why we are very meticulous about your artwork.

We develop all coin designs from scratch. Email us at hello@aviatorgear.com and let's get started.

The preferred format is a vector file of type .EPS or .AI. A high-resolution JPG or PNG of 300 dots per inch (dpi) is the second best. Native file formats in Corel Draw, Photoshop, or Adobe Illustrator, and PDF documents also work great. We can accept and modify pretty much any type of file, such as .jpeg, .gif, .png, .ppt, .doc, .pdf, .bmp, .tiff, .psd, or .pub.

Most challenge coins range from 1.5 to 2 inches in diameter, with 1.75 inches being the standard size. We also produce custom military challenge coins up to 6 inches in diameter. Custom sizing is available to meet your unit’s specifications.

Absolutely! We can manufacture your coin in any shape, with 3-dimensional images and cut-outs. Lots of cool examples HERE!

Yes. We specialize in custom challenge coins with unique shapes, detailed edging styles, vibrant color options, engraved names and numbers, and 3-dimensional sculpting. Functional features such as built-in bottle openers can also be incorporated into your design.

Our custom challenge coins are produced using premium materials with a wide selection of plating finishes and edging styles. These options allow you to create military challenge coins that reflect your unit’s personality and stand out visually.

Depending on your design, we will use brass, iron, or zinc alloy as the base material. Your coin will then be electroplated with any of our many choices of metal plating options.

Check out our Coin Plating Guide and our Coin Plating Galleries!

Many suppliers sell you an epoxy coating as a protective measure for your coin, which we believe is unnecessary. An epoxy coating takes away from the vibrancy of the coin and dulls the colors and the intricate details. The times we will recommend epoxy are when your design has a large area of enamel color, such as our 2" diameter round bottle openers, or to protect screen-printed designs.

Yes. We regularly produce bulk custom challenge coins for military teams, aviation units, and large organizations. Our production process ensures consistent craftsmanship and uniform quality across every coin in large quantity orders, making bulk purchasing ideal for deployments, graduations, anniversaries, and recognition programs.

Yes. We create engraved commemorative coins for aviation units and military teams to honor retirements, promotions, aircraft retirements, mission milestones, and special achievements. These coins are designed to preserve history and recognize service in a meaningful and lasting way.

Our high-quality unit challenge coins are built for long-term durability. They are suitable for daily carry, ceremonial presentation, or display. Each coin is manufactured using proven methods that ensure strength, clarity of detail, and lasting finish quality.

Timelines vary depending on order size and complexity. After your design is approved, production begins. Our team works to maintain consistent quality while keeping timelines on track for both standard and bulk custom challenge coin orders.

You can expect shipment about 5 weeks after final artwork approval.

We do not have a rush production program; we will do what we can to meet your deadline. We manufacture our challenge coins as quickly as possible while maintaining the highest quality standards.

We do not sell to the public or maintain an inventory of any of our challenge coins. All of our coins are made to order just for you. All of the designs you see on our website are strictly for customer reorders and to proudly showcase examples of our work. We would never sell your unit's coin to anyone else.

Not sure, perhaps vanity or free advertising at your expense? We will never deface your challenge coin. Some companies justify this as a way to remind the customer when time to reorder. Our view is that, if we do our job, you are not only going to remember who made your coin, but also rave about the quality and our customer service to all of your friends.

Aviator Gear focuses specifically on military and aviation challenge coins. We understand unit traditions, insignia standards, and aviation symbolism. From one-of-a-kind commemorative pieces to large-scale squadron orders, we deliver custom challenge coins that reflect pride, precision, and professionalism.