Mint condition

When the U.S. Mint opened in 1792, it made 11,173 copper cents in the first year. Today, 750 coins are produced in a minute with high-speed machines.

Although improved production techniques create coins more efficiently than when the U.S. Mint started, the original intention remains the same, says Henrietta Holsman Fore, director of the U.S. Mint in Northwest.

“Coins reflect the values, the character and the history of our nation,” she says. “They are emblems of our civilization. From a very modern point of view, when they end up traveling in our pockets around the world, they are ambassadors for our country.”

This year, the U.S. Mint will produce between 15 billion and 18 billion coins, making an average of $6.5 million a day at mints in Philadelphia and Denver. Because all coins are made for less than their face values, last year the organization made about $1 billion in profits, which went into the General Fund of the Treasury. The average coin can remain in circulation about 25 to 30 years.

Ms. Fore believes a coin renaissance is under way, especially with the release of a newly designed quarter every 10 weeks through the 50 State Quarters program. Also, after the introduction of the European euro in 2002, she says the U.S. Mint has been considering a national coin redesign.

Before any new pattern is stamped on metal, however, John W. Snow, secretary of the U.S. Department of the Treasury, must approve it, says Ron Harrigal, assistant director for design and research and development at the U.S. Mint. For instance, this process was used before the text was changed and the size of George Washington was reduced on the coins in the 50 State Quarters program.

Once Mr. Snow gives the green light, Mr. Harrigal says a three-dimensional, 11-inch circular model is made of the new coin in clay or wax. The model is then critiqued for certain parameters, such as the amount of relief on either side of the coin. The contour on each side needs to be equal so there’s not too much metal on one face.

“When you make the coin, it’s pressed between two negative images,” Mr. Harrigal says. “They are fighting for the metal flow. We need to make sure they are balanced to work in vending machines. The machine must recognize it as balanced to buy a can of soda.”

A plaster copy of the 11-inch model is made, which, in turn is used to make a negative form of the new coin in rubber. The rubber form is used to create a positive, 11-inch model in epoxy.

A transfer engraving machine creates a coin-size copy of the 11-inch epoxy model in steel. The result, called a master hub, is used to press a master die in a negative form. Positive-relief work hubs are made from the master die, and from those work hubs, negative-form work dies are made.

“Work dies make the coins,” Mr. Harrigal says. “We need to make sure we can make 1,000 of these work dies. If you have a work hub crack, you need to be able to make coins from another work hub from the master die.”

The amount of detail on the faces of coins always excites Mr. Harrigal. Although pennies are tossed around as if they are a dime a dozen, he says the patterns’ creators scrutinize the images.

“We look at them with magnifying glasses,” he says. “We ensure the design will look right. The average person probably hasn’t really looked at a penny, nickel or dime lately. They are miniature works of art in metal that are there for people to appreciate.”

Story Continues →