We don't (yet) have a true long-term solution to the wear and tear we put on our Castle Panic monster tokens, but I've got a possible one. The Wizard's Tower expansion introduced the idea of placeholder tokens. The big monsters get triangle tokens to be put in the bag with the others for random drawing, and when they're selected, they're replaced on the board by the real tokens, which are other shapes (pentagons for the 5-point dragon and chimera, for example).
So, then, with a little 3d printing, I can extend the idea to just about all the monsters. I worked up a basic token-shaped template, made versions with different sets of numbers (every range from just 1 up to 1-4), and started to combine them with various monster models downloaded from Thingiverse. Some of the monsters I've found are big enough to cause problems with my underpowered computer, but there are a bunch of miniatures games which provide very useful critters.
Here, for example, is an ogre:
And here's a troll:
The nifty thing about the troll is that a fire token fits on his axe:
I've only done a few so far (troll, ogre, and goblin cavalry), but eventually, I can probably get enough to replace all of the monsters.