Two-Tone Gold and Silver 3D Badges with Enamel: How They Are Made, Brass or Zinc, and Small Orders
Why buyers ask
In October 2026 a buyer in Finland asked us to quote 50 and 100 pieces of a traditional maritime diving emblem: about 60 mm tall, polished gold with a deep black enamel background, a gold rope border, two small elements in polished silver, raised 3D detail, and two pin fasteners for wear on a jacket or uniform. The questions were the ones most buyers of heritage, unit and association badges ask: can one badge carry both gold and silver, should it be brass or zinc, and will fine details such as a rope border survive.
How a two-tone gold and silver badge is made
- Artwork and mold: the emblem is redrawn as production artwork with raised, recessed and 3D sculpted areas, and the mold is cut from it.
- Casting or striking: the badge blank is die-cast (zinc alloy) or die-struck (brass), then trimmed and polished. Polishing before plating is what makes a "polished gold" finish bright.
- First plating: the whole badge is plated in the first color, for example gold.
- Masking and second plating: the areas that must stay gold are covered with a resist, and the badge is plated in silver (or the other way round). The mask is then removed.
- Enamel: black enamel is filled into the recessed background. Soft enamel leaves the metal edges raised; hard enamel is polished flat with the metal.
- Fasteners and packing: pins or posts are soldered to the back and each badge is packed separately.
Because masking is done by hand, a clean color boundary needs a raised line, edge or step between the gold and silver areas. Two colors meeting on a flat, smooth surface are harder to separate neatly.
Brass or zinc alloy?
| Die-cast zinc alloy | Die-struck brass | |
|---|---|---|
| Best for | Sculpted 3D relief, rounded shapes, cut-outs, multi-level detail | 2D and shallow relief, crisp edges, flat enamel areas |
| Fine raised detail (rope borders, texture) | Reproduced well by the casting mold | Very crisp on shallow relief; deep sculpting is limited |
| Polish and weight | Bright after polishing; lighter | Very bright, dense and heavier |
| Cost | Usually lower for 3D designs | Usually higher material cost |
For a badge described as "3D embossed", zinc alloy is normally the practical choice. If the design can be expressed in flatter relief and you want the feel of a heavier metal, ask for a brass quotation alongside it. See zinc alloy vs brass vs iron for the full comparison.
Keeping fine details
- Size helps: at about 60 mm tall, a helmet, anchor, rope border and small figures can all be kept; the same design at 30 mm would need simplifying.
- Very thin lines may fill with plating or enamel; the production artwork review is where line widths are thickened slightly if needed.
- Enamel needs a pool: color can only sit in recessed areas with a metal edge around them, so the black background is designed as recesses between the raised elements.
- Photos are enough to start: if you have no vector file, we redraw from clear photos and show the result in the proof.
Fasteners for uniforms and jackets
Two fasteners stop a larger badge from rotating. Common choices are butterfly or rubber clutches, safety-catch pins, and screw-back posts with a nut for thick fabric or permanent wear. Tell us how the badge will be worn and we will suggest one; the proof shows the fastener type and position.
What drives the price of 50–100 pieces
- The one-time mold and artwork, which weigh more at small quantities (see mold fees explained).
- Size and thickness, and zinc alloy versus brass.
- Two-tone plating, which adds masking and a second plating step per piece.
- 3D sculpting, hard versus soft enamel, number of fasteners and individual packaging.
- A physical sample before production, and shipping to your country.
Our prices are quoted per design and quantity; send the artwork and the quantities you are comparing, and we quote each one with the tooling and shipping shown separately. If the emblem belongs to an organization, make sure you have permission to reproduce it.
Frequently asked questions
Can one badge have both gold and silver plating?
Yes. Two-tone badges are plated in one color first; the areas that must stay that color are masked, and the badge is plated in the second color before the mask is removed. It adds hand work and cost per piece, and it works best when the two colors meet at a raised edge or step in the design.
Is brass or zinc alloy better for a detailed 3D badge?
For sculpted, multi-level 3D relief, die-cast zinc alloy is the usual choice because the casting mold reproduces rounded shapes and fine raised texture well. Die-struck brass gives crisp edges and a very bright polish and suits flatter, 2D or shallow relief designs. Ask for a material recommendation based on your artwork.
Can you make 50 or 100 custom badges?
Yes. Small quantities are normal for custom badges; the one-time mold and artwork are a larger share of the cost at 50–100 pieces, so the unit price drops as quantity rises. Two-tone plating, 3D relief and enamel each add to the unit price.
Can you work from a photo of an old badge?
Yes. Our designer redraws the emblem from photos and sends a digital proof that marks raised and recessed areas, which parts are gold or silver, the enamel color, size and fasteners for your written approval before the mold is made.
Get your badge quoted
Send photos or artwork, size, quantities, which parts are gold, silver and enamel, and how the badge will be worn. Quote response within 24 hours.