Originally posted by Ноnоr
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Even so, for the examples with the remarkably consistent outlines, I wager a trimming stamp is used first and then a bit of fine-tuning by hand which accounts for the signs of hand finishing that you're seeing. Also, the thinner the planchet (and these are much thinner than any other KM badge) the more shear force distortion of the margins from the trimming stamp which could further contribute to the small differences you're seeing. By contrast, the fully hand-cut examples show wild variability.
This duplicity of techniques is common in other Kriegsmarine awards; we see the same for Schwerin's, Meybauer's and Juncker's early Tombak U-Boat badges which start with more variable hand-cuts in the early variants that are later replaced by standardized trimming stamps requiring only touchups.
Best regards,
---Norm
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