I posted this in the Challenge Coin Association on eBay:

I plan on making around 400 unique custom coins a month using a lost wax casting process. I plan on having only one standard size of coin to make things as easy as possible. I’m doing orders of one. Yes, the quality of cast coins is not as good as die struck coins, but I’m using the equipment I have. Also I am getting into to this more for the designs and not the final product. Coins are just an easy start. It could be anything smaller and flat.

What size should I choose? Challenge Coins are new to me, but seem to be the largest type of custom coins. I am thinking of the 1 1/2″, 38.1mm size, as this seems to be a standard challenge coin. This is a silver dollar size.

What about Thickness? I would like to go with 3mm, because I am going to let people design ½mm into the coin each side leaving me with a 2mm thick center at times.

2mm think seems to be something of a standard, but I think a 1mm center is too thin as I am not stamping, but casting.

I don’t know why I am beating myself up on this. I just need to start making coins and see what people tell me.

A 1 ½ inch by 3mm coin seems a little big to carry in a pocket or to be on a key chain. A pendant would be way too big. What do you think? You guys carry these coins. If you look at history silver dollars were never really used. I tried carrying around a silver dollar and I thought it was too big. I thought a half dollar was perfect. Before I really started looking at challenge coins I thought the half dollar size was the best.

With a lower price for a single custom coin I see coins based on personal goals, affirmations, and constitutions a bigger market then challenge coins. I see these coins being carried not just displayed. The coin designers will determine the market, but am I am just trying to come up with a great size.

Thanks much for your input,

Paul Krush