Custom Soft Enamel Badge Price: Why Size, Detail and Color Versions Change the Quote
A real example: same buyer, three versions
In September and October 2026 a first-time buyer in the UK asked us for about 100 soft enamel badges, with raised lines he could feel. The design and size changed several times, and each change was quoted again. The ranges below are rounded and do not include shipping or import duty.
| Version | What changed | Mold fee (one time) | Unit price |
|---|---|---|---|
| First design, about 27 mm tall | Simpler artwork, single color scheme | Under US$100 | Under US$1 per piece |
| Same design at about 35 mm, 100 pcs split into 4 color versions (40/20/20/20) | Bigger badge and four small color batches from one mold | About US$450 all-in for 100 pcs, including design, mold, production and shipping | |
| New detailed design, about 35–40 mm, one color scheme | More fine detail, raised black line work, shaped outline with figures | About US$150–180 | About US$2.00–2.30 per piece |
The buyer's first question about the last quote was whether the extra cost came from cutting around the shaped outline. Mostly it did not: the larger size and the much more detailed artwork were the main reasons.
What actually drives the price
- Size and weight. A 35–40 mm badge uses far more metal than a 27 mm one (area grows with the square of the size), needs a larger mold and has more surface to plate and polish.
- Detail and line work. Fine raised lines, small lettering and many small enamel areas take more engraving time on the mold and more care when filling. Very thin lines also need a finer mold to come out clean.
- Number of enamel colors. Soft enamel is filled color by color, so each extra color is another step on every badge.
- Outline and cut-outs. The outline is cut with tooling made once, so a shaped outline mainly affects the mold. Internal cut-outs, thin points and narrow gaps add more work than a smooth outline.
- Color versions. One mold can make several color versions, but each version is a separate color setup and batch. 100 badges in one scheme cost less than 100 badges split 40/20/20/20.
- Quantity. Setup and handling are shared across the order, so 100 pieces cost more per piece than 300 or 500.
- Extras. Plating color, backing type and sequential numbering on the back (usually laser engraved) are quoted per piece.
How to keep a badge within budget
- Decide the final size before asking for a final quote; compare against a badge you already own.
- Keep one color scheme for the first order and add color versions in a later run; the mold is reused, so you only pay the color setup then.
- Simplify very small details that will not be visible at badge size.
- Tell us your target price or total budget: we can suggest changes to size, thickness, colors or plating that keep the look of the design.
From quote to finished badges
- You send the design and, ideally, each element as a separate high-resolution file, especially small icons.
- The mold fee is arranged (for small first orders we invoice through PayPal).
- We prepare production artwork and send it for approval. Changes such as thinner black outlines are made here, and production does not start until you approve.
- A physical sample is made in about 7 days; after sample approval, production takes about 7 days and courier delivery about 7 days.
Custom orders can start at 10 pieces once the mold fee is paid. See custom badge MOQ: 10, 50, 100 and 300 pieces and hard vs soft enamel for the other choices that affect price.
Frequently asked questions
Why did my badge price go up when I made it bigger?
A larger badge uses more metal, needs a larger mold and has more enamel area to fill and more surface to plate and polish. Going from about 27 mm to about 35–40 mm with a more detailed design moved one recent 100-piece quote from under US$1 to about US$2 per piece, and the one-time mold fee from under US$100 to about US$150–180.
Does cutting around a shaped outline cost extra?
A little. The outline is cut by tooling made once, so a shaped outline mainly adds to the mold work. Internal cut-outs, very thin points and many small details add more, but size and the amount of detail and color usually matter more than the outline itself.
Can one mold make several color versions of the same badge?
Yes. The mold fee is paid once and each color version uses the same metal base with different enamel colors. Each version is a separate color setup, so splitting a small order into several small batches raises the price per piece; keeping one color scheme for the whole order keeps it lowest.
Will I see the artwork before production?
Yes. After the mold fee is arranged we prepare production artwork from your files and send it for approval. Tooling and production start only after you approve it, and changes such as thinner black outlines are made at that stage.
How long does a 100-piece soft enamel badge order take?
A physical sample is normally made in about 7 days after artwork approval and the mold fee, production takes about 7 days after sample approval, and courier delivery about 7 days. Allow extra time for artwork revisions and import duties.
Get your badge quoted
Send your design, the size you want, quantity, number of color versions and delivery country. Quote response within 24 hours.