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Another thought/possible cause is the side-side width dimension of a planchet strip (in conjunction with the relatively minor thickness by comparison) should make it subject to tiny width dimensional changes via either production tolerances or environmental changes. What would this take, maybe a whole 0.5mm shrinkage across the entire width of a strip?
From what I've seen the distance between punches can be smaller than .5mm, but sometimes between 1-2mm. Assuming a normal distribution of the punching process, the smallest clips will be the most common.
The tinniest clips don't cause any weakness of the design rim and are virtually impossible to see on solid alloy coins. These go unnoticed. On a clad coin, however, the reversal of the clad layer on the edge is sometimes the only indication that a clip occurred.
Edited by ErrorCoins222
04/30/2015 3:25 pm