The question is, can we trust our blacksmiths with all that silver, or will orion go out and use it to buy raffia and taffeta? 
Just kiddin', brother. That's actually a bad-ass idea. Have you seen the challenge coins yet? Can you match that quality?
Sister, my middle NAME is Quality.
Sure, with no effort and very little capital investment!
Unfortunately my first name is Pilesof and my last name is Bullshit.
I'd have to melt down a few silver rounds and give it a shot. The only problem will be the back face, but silver casts like a champ, so I figure with a halfway decent mold it'd do pretty well. The biggest issue is air bubbles, and with a little vacuum pump and a preheated mold,that's not an issue.
What kind of quantity do you anticipate being able to sell?
Assume 80% of the current demand for the coinage?
I foresee making the molds/consulting on having them made and then handing the operation over to someone with more spare time/opportunity for profit, as opposed to becoming a supplier - just 'cause I already have my plate full as hell with some outside obligations.
Maybe over the summer/fall, though, I could make a few hundred in a week or two. (should be able to cast about ten an hour, if you have your shit straight on melt times and mold cooling/preheat times. A toaster oven would preheat the mold adequately, and one of those flamethrower propane torches for killing weeds or heating roofing tar would melt the silver in a graphite crucible - 4 ounce graphite crucibles run about 10 bucks for three at harbor freight btw.
Since it's silver, you could use a stainless steel cup to melt it in, but you might get brazing, so I'd stick with graphite. Might need to passivate (parkerize/hot blue) the steel mold if you get adhesion between the silver and the steel. Maybe even chrome plating - I think the solubility of iron oxide in silver is pathetic, though, so hot blueing would be the best bet, since parkerizing is a phosphate conversion, and phosphor's an awful lot like sulfur in alot of instances.
Dammit don't ask me these questions after I've watched Iron Man... AGAIN...
Who else do you know that can build repulsors out of a few yards of taffeta, a coconut, a pound of nails, and a sheet of paper?
Sincerely,
Raffia Boy
