Custom challenge coins with cutouts are a distinctive alternative to traditional solid round coins. Instead of filling the entire metal surface, the design includes one or more open areas, windows or negative spaces that allow the background to show through.
Cutouts can be used to create aircraft silhouettes, stars, lettering, shields, animals, architectural shapes, logos and other custom forms. They are especially useful when the goal is to make a challenge coin look lighter, more modern or visually different from a standard solid design.
However, cutout coins require careful engineering. The openings affect the strength, tooling, enamel layout, edge structure and overall manufacturing process, so the design should be reviewed by the manufacturer before production.
What Is a Challenge Coin With a Cutout?
A cutout challenge coin is a metal coin that contains an intentional opening within its design.
Instead of:
Solid metal → Center artwork → Outer edge
the design may look like:
Outer metal frame → Open center → Raised details
The opening can be:
- Small
- Large
- Symmetrical
- Asymmetrical
- Decorative
- Functional
- Part of the logo
- Part of the overall coin shape
For example, an aviation challenge coin could have an aircraft silhouette with openings between the wings and fuselage.
Why Choose a Cutout Challenge Coin?
Cutouts provide several design advantages.
Unique Appearance
A cutout immediately differentiates the coin from a conventional solid design.
More Negative Space
Open areas can make a complicated design feel less crowded.
Lightweight Construction
Removing some metal can reduce the overall weight compared with an otherwise similar solid design.
Strong Visual Contrast
The background can become part of the design.
Better Representation of Certain Shapes
Some subjects naturally benefit from openings.
Examples include:
- Aircraft
- Fire trucks
- Gears
- Stars
- Letters
- Buildings
- Animals
- Tools
Popular Cutout Challenge Coin Design Ideas
1. Aircraft Cutout Coins
Aviation organizations can use openings to emphasize:
- Aircraft wings
- Propellers
- Rotor blades
- Tail sections
- Cockpit shapes
A cutout can make an aviation coin look more dynamic than a standard circular coin.
2. Star Cutout Coins
A star-shaped opening can be used in:
- Military coins
- Police coins
- Recognition coins
- Patriotic designs
- Anniversary coins
The center of the star can remain open while the surrounding metal forms the frame.
3. Shield Cutout Coins
Shield designs work well with negative space.
For example:
Outer shield
Open center
Raised badge
This can be suitable for law enforcement, security and professional organizations.
4. Letter Cutouts
A company or organization can incorporate a large letter into the coin.
For example:
A
or:
K9
The negative space becomes part of the identity of the coin.
5. Animal Silhouette Cutouts
K9, military and wildlife-related organizations can use animal silhouettes.
Potential subjects include:
- Dogs
- Eagles
- Horses
- Wolves
- Bears
A cutout can emphasize the outline of the animal while keeping the coin visually lightweight.
6. Gear-Shaped Cutouts
Gear elements are useful for:
- Engineering organizations
- Automotive companies
- Maintenance teams
- Manufacturing groups
- Technical schools
The openings between the teeth can create natural negative space.
7. Building Cutouts
An organization can use the outline of:
- Headquarters
- Historic buildings
- Universities
- Fire stations
- Landmarks
The open areas can help preserve the building’s silhouette.
Cutout Challenge Coins for Different Applications
Military
Cutouts can be used for:
- Unit insignia
- Aircraft
- Special operations themes
- Deployment commemorations
- Anniversary coins
A military coin could combine:
Unit emblem + aircraft silhouette + cutout border
Police
Law enforcement coins can use:
- Shield cutouts
- Badge shapes
- Stars
- City skyline designs
- Department initials
For example:
Police badge
inside a cutout shield.
Fire Departments
Firefighter designs can incorporate:
- Maltese crosses
- Fire helmets
- Fire trucks
- Station numbers
- Department initials
A Maltese cross cutout can create a particularly recognizable design.
K9 Units
K9 coins can combine:
Dog silhouette + K9 text + open negative space
The cutout can help emphasize the dog’s profile.
Aviation
Aviation is one of the strongest applications for cutout coins.
Possible designs include:
- Aircraft
- Helicopters
- Propellers
- Wings
- Airport terminals
- Runways
A cutout can be used to create open space around aircraft components.
Corporate Recognition
Corporate coins can use cutouts for:
- Company initials
- Logos
- Product silhouettes
- Anniversary numbers
- Geometric patterns
The style can be modern and minimalist.
Cutout vs Solid Challenge Coins
| Feature | Cutout Coin | Solid Coin |
|---|---|---|
| Appearance | More open and distinctive | Traditional |
| Negative Space | High | Low |
| Weight | Can be lower | Usually higher |
| Design Flexibility | High | High |
| Structural Requirements | Higher | Lower |
| Manufacturing Complexity | Can be higher | Usually simpler |
| Best For | Modern/custom designs | Traditional recognition |
A cutout isn’t automatically better than a solid coin. The choice should depend on the design and intended application.
How Are Cutout Challenge Coins Made?
A simplified manufacturing workflow is:
Artwork
↓
Engineering Review
↓
Tooling
↓
Metal Forming
↓
Cutout Creation
↓
Polishing
↓
Plating
↓
Enamel
↓
Quality Inspection
↓
Packaging
The exact manufacturing process depends on the material, coin structure and cutout design.
The Importance of Structural Strength
One of the most important issues with cutout coins is maintaining enough metal around the opening.
If a narrow metal section is too thin, it may become:
- Weak
- Easily bent
- Difficult to manufacture
- Vulnerable to deformation
Therefore, the manufacturer should review the structural areas before tooling.
Avoid Extremely Thin Bridges
A bridge is the section of metal connecting two parts of the coin around a cutout.
For example:
Metal → Open area → Metal
The connecting metal must be strong enough for production and normal handling.
Avoid designs where important sections are connected by extremely thin lines.
The appropriate minimum depends on:
- Material
- Coin size
- Thickness
- Production method
- Shape
- Relief
Therefore, the manufacturer should confirm the practical dimensions rather than relying on a universal number.
Cutout Size Matters
Large openings create a stronger visual effect but also remove more structural material.
Small openings may be easier to integrate into the design.
A good design balances:
Visual Impact + Structural Strength + Manufacturing Feasibility
Cutout Coin Materials
Common metal options include:
Brass
Useful for traditional metal coins and detailed designs.
Copper
Provides a warm metal appearance and can work well with antique finishes.
Zinc Alloy
Useful for complex shapes and relief designs.
The ideal material depends on the coin’s:
- Size
- Shape
- Thickness
- Relief
- Finish
- Quantity
Cutout Coins With Enamel
Cutouts and enamel can be combined.
For example:
Gold-plated metal frame
Blue soft enamel
Open center
This creates three distinct visual elements:
- Metal
- Enamel
- Negative space
Soft Enamel Cutout Coins
Soft enamel can be used in recessed areas around the cutout.
Advantages include:
- Strong color contrast
- Textured appearance
- Flexible color combinations
However, the metal borders separating enamel sections need sufficient definition.
Hard Enamel Cutout Coins
Hard enamel creates a smoother surface.
A combination such as:
Antique gold + hard enamel + open cutout
can create a premium commemorative appearance.
The manufacturer should confirm that the enamel layout is compatible with the available metal structure.
2D Cutout Challenge Coins
2D relief is a natural option for many cutout designs.
It works well for:
- Text
- Logos
- Simple symbols
- Geometric shapes
A cutout can provide the main visual distinction without requiring complex 3D modeling.
3D Cutout Challenge Coins
3D relief can be combined with cutouts for a more complex design.
For example:
3D eagle
open wing sections
or:
3D aircraft
cutout between structural components
This can create a highly dimensional product.
However, the more complex the combination becomes, the more important the engineering review is.
Cutout Challenge Coin Edges
The edge should be considered together with the cutout design.
Possible options include:
- Flat edge
- Rope edge
- Reeded edge
- Oblique edge
- Custom edge
A decorative edge can reinforce the overall design, but the coin should not become visually overloaded.
Border Design for Cutout Coins
A cutout coin can use a conventional outer ring.
For example:
Outer ring
→ organization name
Center
→ cutout logo
This creates a useful separation between information and the primary visual element.
A double border can also be used if sufficient space is available.
Where Should Text Go?
Text can be placed:
- Around the outer ring
- Above the cutout
- Below the cutout
- On the reverse
- Along the edge
Avoid putting too much text near a complex opening.
A simple arrangement is:
Front
Organization Name
Cutout Logo
Reverse
Recognition Message
Date
This keeps the design readable.
Can You Put a Serial Number on a Cutout Coin?
Yes.
A serial number can be placed on:
- Reverse
- Outer ring
- Metal bridge
- Edge
For example:
No. 025/500
However, don’t place the number on a narrow bridge where there isn’t enough space.
Numbering should be included in the original artwork and manufacturing specification.
Cutout Coin Design for Limited Editions
Cutouts can work particularly well for collector-oriented products.
Example:
500-piece edition
Front:
Custom emblem with open center
Reverse:
25TH ANNIVERSARY
No. 025/500
The combination of a unique shape and serial numbering can make the coin more distinctive.
Common Cutout Manufacturing Problems
1. Metal Sections Are Too Thin
This can reduce strength.
Solution
Increase the thickness or simplify the opening.
2. Cutout Is Too Complicated
Too many tiny openings can make production difficult.
Solution
Simplify the negative space.
3. Enamel Areas Are Too Small
Small enamel sections may be difficult to fill cleanly.
Solution
Increase the enamel area or simplify the color layout.
4. Small Text Becomes Unreadable
This is especially common around narrow rings.
Solution
Use larger text, shorten the wording or increase the coin size.
5. Cutout Changes the Coin’s Balance
Removing a large amount of metal can change how the coin feels.
Solution
Consider symmetry and material distribution during design.
6. Packaging Does Not Protect the Open Sections
Thin bridges can be more vulnerable to impact.
Solution
Use packaging that prevents coins from rubbing against each other.
How to Design a Better Cutout Challenge Coin
Follow these steps:
Step 1 — Identify the Main Shape
Decide what the cutout represents.
Step 2 — Simplify the Silhouette
Remove unnecessary tiny details.
Step 3 — Check Structural Areas
Make sure the remaining metal sections are sufficiently strong.
Step 4 — Add the Border
Reserve enough room for text or decoration.
Step 5 — Add Enamel
Use color only where it improves the design.
Step 6 — Select the Finish
Choose bright or antique plating according to the intended style.
Step 7 — Review the Engineering
Ask the manufacturer to confirm that the design can be manufactured reliably.
Step 8 — Approve the Proof
Do not begin tooling until the final design has been confirmed.
Example: Custom K9 Cutout Challenge Coin
Front
Large K9 silhouette
Open area between the dog’s body and surrounding frame
K9 UNIT
Reverse
LOYALTY • SERVICE • COURAGE
2026
Finish
Antique silver
Enamel
Dark blue
Edge
Rope edge
This design uses the cutout as a primary visual element rather than simply adding an opening for decoration.
Example: Aviation Cutout Challenge Coin
Front
Aircraft silhouette
Open sections around the wings
Airport emblem
Border
AVIATION UNIT • SERVICE • EXCELLENCE
Reverse
2026
SPECIAL RECOGNITION
Finish
Antique gold
This combination can create a strong aviation identity while maintaining a recognizable silhouette.
Example: Corporate Cutout Recognition Coin
Front
Company initials as a cutout
Border
25 YEARS • INNOVATION • EXCELLENCE
Reverse
EMPLOYEE RECOGNITION
2001–2026
Finish
Bright silver
A minimalist cutout can be particularly effective for modern corporate branding.
How Much Do Cutout Challenge Coins Cost?
The final price depends on multiple factors, including:
- Quantity
- Coin diameter
- Thickness
- Material
- Tooling complexity
- Number of cutouts
- 2D or 3D relief
- Enamel
- Plating
- Edge design
- Packaging
A cutout design can require more engineering than a simple solid coin, especially when it contains complex openings or custom shapes.
For an accurate quotation, provide the manufacturer with the final artwork and specifications.
How Long Does Manufacturing Take?
Production time depends on:
- Artwork complexity
- Tooling
- Quantity
- Finishing requirements
- Enamel
- Packaging
- Quality inspection
A simplified design can generally be easier to produce than a highly detailed cutout with multiple finishes.
Always confirm the actual production schedule with the manufacturer before setting an event deadline.
How to Inspect Cutout Challenge Coins Before Delivery
Check:
Shape
Does the opening match the approved artwork?
Structural Areas
Are the metal bridges intact?
Surface
Are there scratches, dents or visible defects?
Plating
Is the finish consistent?
Enamel
Are colors clean and properly filled?
Dimensions
Does the coin match the approved size and thickness?
Edge
Is the edge pattern correct?
Quantity
Is the correct number of acceptable coins packed?
Custom Cutout Challenge Coins From ChallengeCoinBadges
ChallengeCoinBadges provides custom metal product manufacturing for organizations looking for distinctive challenge coin designs.
Custom options can include:
- Cutout challenge coins
- Custom-shaped coins
- 2D challenge coins
- 3D challenge coins
- Soft enamel
- Hard enamel
- Antique finishes
- Bright finishes
- Rope edges
- Reeded edges
- Custom edges
- Serial numbering
- Custom packaging
The same manufacturing capabilities can also be used for military coins, police coins, firefighter coins, K9 coins, aviation coins, medals, badges, lapel pins and keyrings.
ChallengeCoinBadges Official Website
Email: sales@challengecoinbadges.com
When requesting a quotation, provide:
Artwork + Quantity + Diameter + Thickness + Material + Cutout Details + Finish + Enamel + Edge + Packaging
This allows the manufacturer to evaluate the design before tooling.
Frequently Asked Questions
What is a cutout challenge coin?
It is a custom metal coin containing one or more intentional openings or negative-space areas.
Are cutout challenge coins stronger than regular coins?
Not necessarily. Removing metal can reduce structural strength, so the design must maintain sufficiently strong connecting sections.
Can cutout coins have enamel?
Yes. Soft or hard enamel can be combined with suitable cutout designs.
Can cutout coins be 3D?
Yes. 3D relief and cutouts can be combined when the design is properly engineered.
Are cutout challenge coins more expensive?
They can be, depending on the complexity of the tooling, shape and production requirements.
Can cutout challenge coins have custom edges?
Yes. Depending on the design, options can include rope, reeded, flat and other custom edge treatments.
Can I add text to a cutout challenge coin?
Yes, but the available space should be considered carefully. Small text around narrow areas may not be easy to read.
Can cutout challenge coins be numbered?
Yes. Serial numbers can be placed in a suitable metal area, usually on the reverse or outer ring.
What material is best for a cutout challenge coin?
Brass, copper and zinc alloy can all be used depending on the design. The manufacturer should recommend the appropriate option based on the coin’s size, thickness and structure.
Final Thoughts
Custom challenge coins with cutouts offer an excellent way to create a product that looks different from a traditional solid coin.
The most successful designs usually follow three principles:
Simple Negative Space
Strong Structural Areas
Clear Visual Hierarchy
Whether you’re designing a military aircraft coin, police badge coin, firefighter coin, K9 recognition coin, aviation coin or corporate recognition product, the cutout should have a purpose rather than simply being decorative.
Before production, have the manufacturer review the cutout dimensions, metal bridges, text, enamel areas, relief and overall structure.
A well-engineered cutout can transform a standard challenge coin into a distinctive recognition product while maintaining the durability expected from a professionally manufactured metal coin.