Challenge Coin Display
This project was initiated to provide an attractive way to showcase a notable challenge coin, leaning into a military aviation theme. After several idea iterations, it was decided to base a design off of the Brabazon Forgeworks logo, creating an aesthetic and unique way to display a challenge coin.
From Design to Manufacture
Initially, the 2D logo design was sketched within Solidworks, scaling it appropriately to fit an average size challenge coin.
After getting comfortable with the shape, it was extruded and altered to securely fit a challenge coin inside it, whilst simultaneously enabling easy removal. The supporting base was then extruded from the rear of the display, the angle calculated to provide stability and aesthetics.
Once content with the basic design, a prototype was printed out in order to functionally test the optimal print settings and ensure that the item functioned as intended.
After establishing that the base design printed and functioned correctly, fillets and chamfers were integrated into the design to promote its stealthy, aesthetic look.
After the final design was established, further prototypes were created, each one utilising differing print orientations and settings to validate the best print optimisation for a smooth print with a limited post-processing requirement.
Although optimised for the best quality print, the model still requires a degree of post-processing to ensure a smooth finish across all surfaces.
This process is now the backbone of the Shadow Challenge Coin Display manufacturing process, which can now be purchased from our products page.