To begin with, the manufacture of genuine casino chips (known in the trade as “checks”) is more complicated than one might think – as you suspect, they’re not just discs of colored plastic. They are created, machined, and finished using very specialized equipment, and generally feature several antifraud measures ranging from serial numbers to embedded microchips, as well as each individual casino’s own logo and related branding. Casino chip production is handled by the security printing industry, which also makes things like checkbooks and credit cards. Every stage of manufacture, from the sourcing of raw materials to the delivery of the finished goods, is governed by strict security checks and protocols. Trying to create counterfeit chips that are a perfect match for the real thing, in terms of appearance, weight, and feel, is more or less impossible, even before you start worrying about microchips and suchlike.
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