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The Birth of a Pin
By Larry of Dizneypins.com
In this article, we hope to show you just how much
it takes to make a pin.
The first step is to figure out why you want a pin. In the examples to
follow Dizneypins.com needed a pin to send exclusively to pin meets we
sponsor. Now you need to think of a design, something eye catchy and says
what you need it to say. Next is to choose a type of pin you wish to make.
Here are a few different types of pins.
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| Classic Cloisonne' |
Synthetic or New
Cloisonne' |
Photo Etched |
Die Struck Soft
Enamel |
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| Screen printed |
Epoxy over Litho |
Steel Struck |
Each of these have a different
application and the cost varies.
You need to choose a size and colors for the pin in each case the more
colors and the bigger the pin the more it will cost .
We have decided to make a 1 3/4" pin
with 7 colors and Synthetic Cloisonne'
I am going to tell you how a Classic Cloisonne" pin is produced
The production process for the Classic and Synthetic Cloisonne' is
basically the same. The firing temperature is lower for synthetic.
The
Making of Classic Cloisonne'
Majestic beauty is the tradition of the ancient Chinese art of Cloisonne'.
It was well known in the time of Jingtai of Ming Dynasty (1450--1456) for
the most exquisite production for decorative purposes, the process is used
today in crafting vases and fine and emblematic jewelry. Individually hand
crafted from the initial die to the final polishing, this technique
remains virtually unchanged to this day.
Classic Cloisonne' is refered to by different name Hard Enamel, Real
Cloisonne'
A reverse image
die is crafted and individually struck into the blank copper pieces. The
recessed areas will allow the pin to be color filled. The raised areas
will appear as the detail and the "dividing walls" will separate the
different colors. Also at this time any backstamp is stamped into the
reverse side of main image.
 
Each copper piece is then cut to the exact outline of the design. This is
accomplished by making the cutting dies or piercing tools if a center hole
cut is required.
Cloisonne' powder (a finely ground colored glass) is mixed with a liquid to create a paste-like mixture.
The first Cloisonne' color is filled into the specific recessed areas
with a
small spatula-like instrument
restricted by the "dividing walls"
so that there is no "running" of colors together.
Yes this is done all by human hands.
There are only
96 different Cloisonné colors that can be used in hard enamel pins versus
over 900 colors and shades that can be used in Synthetic Cloisonne' The
pin is then fired 2-4 minutes at 1600 degrees with a fire gun
in order to melt the powdered
Cloisonne'.
This is done for each
color in the design and fired after each color is added to the pin, this
continues for each individual pin for each color. In a order of 1000 pins
with 5 colors means before these pins are finished having Cloisonne' put
in the pin, they
are handled a minimum of 5000 times.
The excess Cloisonne'
pigments now hardened and cooled from the firing are ground away by hand
using a pumice stone wheel.
The pins are
then laid on a sheet of metal, like a baking sheet, and put into an oven
and refired at 1300 degrees to bring back the glossy appearance of the
surface then the pin back attachment is soldered onto each piece (sometimes the pin back is put on in the early stages of this production). Each
pin is then hand tied with a fine copper wire and hung on a plating tree,
which is then dipped into the gold or silver plating finish. The quality
of plating depends upon the length of time each pin is submerged in the
plating liquid. The plating adheres only to the metal surface.
Each piece is polished a final time with a softer polishing wheel in order
to bring out the highest degree of luster and smoothness. These pictures
of this pin are actually a Synthetic Cloisonne and Silk Screened pin. This
was needed to accomplish the fine detail for the printing.
Screen Printed or Offset
Printed pins are
produced the same as a Screen Printed shirt except on a much smaller
scale. Your design is burned onto different screens, one screen for each
color used. Each screen is then laid onto the brass metal that is already
cut to your design and the appropriate color is then applied until each
pin is finished.
New or Soft Cloisonné
Very similar in production to traditional cloisonné except that a special
resin is utilized to provide colors instead of the standard cloisonné
colors. Colors can be matched to Pantone Colors in this type of pin. The
design is die struck into the same type and thickness of metal, a copper
bronze metal surface, as in a true cloisonné pin.
Now if you are not to tired here
is how a Photo- Etched Pin is made
Photo-Etched Pins
One of the first major differences is in the color
selection. Being able to more accurately select the color you want in
photo etching instead of having to select a color that is close to the
one you want from a Cloisonné chart can be very important in the final
overall look of the pin. You can select your own color by going to a
graphics store or a printing shop and asking them to see their Pantone
Color Chart. Every color and shade of color in the Pantone Color Chart
has a 3 or 4 digit number by it.
The next major difference is that a photographic negative, similar to
the same type of negative you get when you use your own camera, is made
of the design. These negatives are then made to the exact size of the
pin design and they are laid out across the surface of the copper bronze
metal that is going to be used. There can be up to 200 or more negatives
laid out on the metal surface. The metal is then dipped into a chemical
solution which etches the image into the metal, forming depressions
where color is to be put. This is why is is named photo-etched pin.
Remember when learning to color in coloring books we were taught not to
get outside the lines with our colors? The same is true in putting the
colors into a photo-etched design. The excavations or depressions are
carefully hand filled with wet enamel colors, one color at a time using
a small eye dropper, brush or toothpick-like instrument until all the
designs on that sheet of metal are color completed. This process is very
delicate, as the enamel colors must not exceed the top of the excavation
or it will bleed and run into another excavation and ruin the pin. Then
the sheet is set aside to air dry. Once the sheet of metal containing
the pin has air dried, it is baked at approximately 450 degrees for
12-15 minutes.
Remember, on the hard enamel pin ( Classic Cloisonne'), the pin had to be hand fired after
each color was put on, requiring much individual handling. The colors
are put in all the photo-etched pins on the metal sheet before the sheet
is put into the oven, much like a pizza oven, to bake. When the sheet of
metal containing the design cools, each individual pin is die cut to its
custom contour. Then each pin, like the hard enamel, has the back
attachment put on and is plated. The final step in a photo-etched epoxy
covered pin is the coating of the pin with clear epoxy.
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