I've always been fascinated with old coins, specifically the hand-struck versions such as Spanish Reales aka "Pieces of Eight" from the 1600-1700's. The process of making coins this way results in every coin having a unique shape, giving them lots of character.
The process begins with melting down 5 ounce .999 silver bars and pouring the molten metal into a bucket of water which breaks up the stream into small segments that I then weigh into 1/2 troy ounce portions.
After melting the small pieces into rough ingots, I flatten them into a coin shape.
I then use custom coin dies that I machined myself to press the silver ingot into a coin.
After cleaning up and polishing the coin edge, I antique the coins and polish the high spots.
Each coin is unique, and made from 1/2 troy ounce of .999 silver. Sizes and shapes vary, but all coins are around 1.125" in diameter.
