Choosing between zinc alloy and brass can significantly affect a custom medal’s weight, appearance, detail, durability, manufacturing process, and overall cost. This data-driven comparison explains the technical differences between the two materials and shows which one is better for sports medals, corporate awards, military recognition, commemorative medals, and large-scale events.

When ordering custom medals, one of the first technical decisions is the base metal. Zinc alloy and brass are two of the most widely used options, but they are not interchangeable.

Zinc alloy is particularly well suited to complex die-cast shapes, 3D relief, recessed details, and large-volume production. Brass offers a traditional solid-metal feel, excellent durability, and a premium perception.

The best choice depends on the medal’s design complexity, required weight, production quantity, finishing requirements, budget, and intended application.

Zinc Alloy vs Brass: Quick Comparison

Property	Zinc Alloy — Zamak 3	Brass — C26000
Typical density	~6.6 g/cm³	~8.53 g/cm³
Typical tensile strength	~283 MPa	~427 MPa at H02 temper
Typical yield strength	~221 MPa	~352 MPa at H02 temper
Typical elongation	~10%	~30% at H02
Melting range	~381–387°C	~916–954°C
Typical manufacturing advantage	Complex die casting	Stamping, forming & machining
3D detail capability	Excellent	Excellent, depending on process
Weight at identical volume	Lower	Higher
Premium solid-metal feel	Good	Excellent
Complex sculpted shapes	Excellent	More process-dependent
Typical use	Sports, events, 3D awards	Premium, military, commemorative awards

The values above are material-property reference values, not guaranteed specifications for every medal. Actual properties depend on alloy grade, temper, manufacturing method, geometry, and processing.

For zinc alloy, ASTM B86 specifies several zinc and zinc-aluminum casting alloys, including Zamak 3, Zamak 5, Zamak 7, Zamak 2, ZA-8, ZA-12 and ZA-27.

For brass, the Copper Development Association lists C26000 as a 70% copper cartridge brass with a density of approximately 8.53 g/cm³. Its H02 half-hard condition has a typical tensile strength of 427 MPa and yield strength of 352 MPa.

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1. Why Material Choice Matters for Custom Medals

The base metal affects almost every part of the manufacturing process.

It influences:

• Medal weight
• Structural strength
• Surface detail
• 2D/3D design capability
• Casting or stamping method
• Plating performance
• Machining requirements
• Production efficiency
• Per-piece manufacturing cost
• Overall tactile quality

A 60 mm zinc alloy medal and a 60 mm brass medal may look almost identical after plating, but they can feel noticeably different in the hand.

This is mainly because brass is considerably denser.

Using the representative densities above:

Brass: ~8.53 g/cm³

Zamak 3: ~6.6 g/cm³

That means brass is approximately:

8.53 ÷ 6.6 ≈ 1.29

or about 29% denser by volume than Zamak 3.

Therefore, if two medals have exactly the same volume, a brass version could theoretically weigh about 29% more before accounting for differences in design, hollow areas, thickness, or manufacturing tolerances.

That extra weight can be desirable for premium awards—but it is not always an advantage.

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2. Zinc Alloy: Why It Is Popular for Custom Medals

Zinc alloy, particularly Zamak alloys, is widely used for die-cast metal products.

ASTM B86 recognizes Zamak 3 as one of the standardized zinc die-casting alloys.

Zamak 3 has a representative density of approximately 6.6 g/cm³, tensile strength around 283 MPa, yield strength around 221 MPa, and elongation around 10% in commonly published die-cast data.

The biggest advantage: design flexibility

Zinc alloy is especially attractive when a medal contains:

• Deep 3D relief
• Sculpted figures
• Animals
• Buildings
• Sports equipment
• Intricate borders
• Multiple levels
• Recessed lettering
• Complex external shapes

The material’s casting characteristics make it possible to produce complicated geometries efficiently.

A technical source from Eastern Alloys describes Zamak 3 as having excellent castability and finishing characteristics for plating, painting, and chromate treatments.

For medal manufacturers, this makes zinc alloy particularly useful when the design requires a 3D die-cast mold rather than a relatively flat stamped profile.

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3. Brass: Why It Is Considered a Premium Medal Material

Brass is a copper-zinc alloy.

For example, C26000 contains approximately 68.5–71.5% copper, with zinc making up the balance apart from controlled minor elements.

C26000 has a density of approximately 8.53 g/cm³, giving it a noticeably heavier feel than Zamak 3.

The Copper Development Association reports typical C26000 tensile strength of:

• 365 MPa — annealed
• 427 MPa — half-hard H02
• 607 MPa — extra-hard H06

The corresponding yield strengths range from approximately 150 MPa to 448 MPa, depending on temper.

This illustrates an important point:

You should never compare “brass” and “zinc alloy” using only one strength number.

The exact alloy and processing condition matter.

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4. Strength: Is Brass Actually Stronger?

In many common comparisons, yes—but the answer needs qualification.

A representative Zamak 3 die-cast value is approximately:

283 MPa tensile strength

while C26000 brass in H02 temper is approximately:

427 MPa tensile strength

That is roughly 51% higher for the cited H02 brass condition.

However, medals are not structural load-bearing components.

For most medals, the more important considerations are:

• Will the medal bend during normal handling?
• Is the ribbon attachment strong enough?
• Are thin sections properly engineered?
• Can the design survive polishing and plating?
• Will the raised details remain sharp?
• Is the final finish consistent?

For a normal award medal, selecting brass simply because it has a higher tensile strength may therefore be unnecessary.

Design and manufacturing quality can matter more than the maximum mechanical strength of the raw material.

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5. Weight: Brass Wins

If your goal is a substantial, heavy medal, brass has a clear advantage.

Using representative density values:

Zamak 3: ~6.6 g/cm³

C26000 brass: ~8.53 g/cm³

Brass is therefore about 29% denser.

For example, suppose a simplified medal design has a solid metal volume of 50 cm³.

Approximate theoretical weight:

Zinc alloy:

50 × 6.6 = 330 g

Brass:

50 × 8.53 = 426.5 g

Difference:

96.5 g

That is approximately 29% more weight for brass.

In a real medal, however, the actual weight will differ because manufacturers may use different thicknesses, recessed areas, cut-outs, hollow sections, and design structures.

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6. 3D Detail: Zinc Alloy Often Has the Advantage

If your medal contains highly sculpted artwork, zinc alloy is frequently the more practical option.

Examples include:

• A 3D firefighter
• A football player
• A military aircraft
• A city skyline
• A detailed animal
• A building
• A championship trophy
• A sculpted mascot

Zamak 3 is specifically recognized as a common pressure-die-casting alloy, and ASTM B86 includes Zamak 3 among alloys used primarily for pressure die castings.

This is important because die casting allows manufacturers to reproduce complicated three-dimensional geometry directly from a precision mold.

Example

A marathon medal featuring a running athlete could use:

Zinc alloy + 3D die casting + antique plating

This combination can create strong contrast between raised and recessed areas.

For a relatively simple circular medal with lettering and a logo, however, brass can be equally appropriate.

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7. Manufacturing Process Differences

Zinc Alloy Medal

A typical zinc alloy medal may follow:

Artwork → 3D engineering → steel mold → die casting → trimming → polishing → plating → enamel → assembly → inspection

Zinc alloy is melted at a much lower temperature than brass.

Zamak 3 has a melting range of approximately 381–387°C, according to published material data.

This makes pressure die casting practical for complex medal designs.

Brass Medal

Depending on the design, brass medals may be manufactured through:

Stamping → cutting → forming → polishing → plating → enamel → assembly

or through other brass-forming and machining processes.

C26000 has a much higher melting range, approximately 1680–1750°F (about 916–954°C) according to Copper.org data.

Therefore, the manufacturing process and tooling strategy are different from zinc die casting.

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8. Which Material Is Better for Detailed Medals?

Choose Zinc Alloy When:

• The design is highly 3D.
• The medal has an irregular shape.
• You need complex relief.
• You want deep recessed areas.
• The order quantity is relatively large.
• You want flexible plating and enamel combinations.
• Weight needs to remain manageable.

Choose Brass When:

• You want a heavier medal.
• The award should feel substantial.
• A traditional metal appearance is important.
• The design is suitable for stamping or forming.
• The medal is positioned as a premium or commemorative award.
• Long-term physical durability is a major consideration.

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9. Cost: Don’t Compare Only the Metal Price

It is tempting to assume:

Cheaper raw material = cheaper medal

but this is not always correct.

Custom medal pricing depends on:

Material + tooling + manufacturing method + size + thickness + quantity + plating + enamel + ribbon + packaging + shipping

A complex zinc alloy 3D medal may require sophisticated mold engineering.

A simple brass medal may have relatively straightforward tooling.

Conversely, a complicated brass design may require additional forming or machining operations.

Therefore, the correct question is not:

“Which metal is cheaper?”

The better question is:

“Which manufacturing process produces the required design at the lowest total cost while maintaining the required quality?”

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10. Study Case: 70 mm Custom Sports Championship Medal

Consider a hypothetical production project for a sports organization ordering 2,000 custom championship medals.

The design requirements are:

• Diameter: 70 mm
• Thickness: approximately 3 mm
• Custom sports figure
• Event logo
• Year
• 3D centerpiece
• Two enamel colors
• Custom neck ribbon
• Gold or silver finish

Option A — Zinc Alloy

A zinc alloy die-cast construction allows the 3D athlete and surrounding details to be integrated into the mold.

Advantages:

• Strong 3D effect
• Complex outline
• Good plating surface
• Efficient production of repeated designs
• Moderate weight

Option B — Brass

Brass provides:

• Higher density
• Heavier hand feel
• Strong traditional appearance
• Excellent material durability

However, if the design contains extensive sculpted relief, the manufacturing method must be carefully evaluated.

Engineering conclusion

For this particular 3D sports-medal scenario, zinc alloy would generally be the first material I would evaluate.

For a premium commemorative medal with relatively flat artwork, brass may be the better choice.

This is a design-engineering recommendation rather than a universal rule. The final decision should be based on the actual CAD artwork, dimensions, thickness, quantity, and manufacturing process.

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11. Study Case: Military Commemorative Medal

Consider another hypothetical project:

A military organization wants a 60 mm commemorative medal featuring:

• Unit emblem
• Eagle
• Establishment year
• Service dates
• Raised lettering
• Antique finish
• Heavy presentation box

The organization wants the medal to feel substantial and traditional.

In this case, brass may be the preferred material because its higher density provides a heavier hand feel, while its copper-alloy composition is well established in metalworking applications. C26000, for example, is widely documented for its forming characteristics and moderate strength.

If the same project required a highly sculpted 3D eagle with a complex irregular outline, zinc alloy would deserve serious consideration.

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12. E-E-A-T: What Should a Professional Medal Manufacturer Evaluate?

A reliable manufacturer should not recommend a material based only on sales price.

A technically responsible evaluation should consider at least:

1. Design Engineering

Review:

• Minimum metal thickness
• Relief depth
• Corner geometry
• Letter size
• Enamel separation
• Ribbon attachment

2. Material Specification

Ask for the actual alloy designation.

For zinc, this could be:

Zamak 3 / ASTM AG40A

ASTM B86 provides standardized alloy designations and chemical requirements for zinc and zinc-aluminum casting alloys.

For brass, specify the actual alloy rather than simply writing “brass.”

For example:

C26000

Copper.org documents its chemical composition, mechanical properties, physical properties, and fabrication characteristics.

3. Production Method

Ask whether the medal will be:

• Die cast
• Stamped
• CNC machined
• Formed
• Combination manufactured

4. Surface Treatment

Confirm:

• Plating type
• Plating thickness/specification where applicable
• Enamel process
• Polishing
• Protective coating
• Color requirements

5. Sample Approval

For large orders, approve a physical sample or production-standard prototype before mass production.

This is particularly important for:

• 3D medals
• Multi-color enamel
• Antique finishes
• Complex logos
• Large medals

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13. Zinc Alloy vs Brass: Which Should You Choose?

There is no universal winner.

Best Overall for Complex Custom Designs: Zinc Alloy

Zinc alloy is often the better starting point for:

• 3D sports medals
• Complex shapes
• Character medals
• Event medals
• Detailed organizational awards
• Large-volume customized medals

Best for Heavy Premium Feel: Brass

Brass is often preferable for:

• Premium awards
• Traditional medals
• Military commemorative medals
• High-end recognition pieces
• Collectible medals
• Designs where substantial weight is desirable

Best for Large 3D Sports Orders

Zinc alloy is usually the first material to evaluate.

Best for a Heavy Traditional Award

Brass is usually the first material to evaluate.

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FAQ

Is zinc alloy better than brass for medals?

Not universally. Zinc alloy is generally more flexible for complex die-cast 3D designs, while brass provides higher density and a heavier, more traditional feel.

Are brass medals heavier than zinc alloy medals?

Yes, when the two medals have the same volume. Representative densities are approximately 8.53 g/cm³ for C26000 brass and 6.6 g/cm³ for Zamak 3, meaning brass is roughly 29% denser.

Which material is better for 3D medals?

Zinc alloy is often the better choice for highly complex 3D die-cast medals because Zamak alloys are designed for pressure die casting and provide good castability.

Which medal material is more durable?

Both can produce durable medals when the alloy, design, manufacturing process, and surface treatment are properly controlled. Brass generally has higher strength in many common wrought conditions, but medals are not structural components, so design and manufacturing quality are equally important.

Does zinc alloy rust?

Zinc alloy does not rust in the same way iron or steel does. However, its surface can oxidize or deteriorate under certain environmental conditions. Proper plating and protective finishing are important for long-term appearance.

Does brass change color?

Brass can naturally develop surface oxidation or patina over time. A suitable plating or protective finish can help maintain the intended appearance.

Which material is cheaper for custom medals?

There is no universal answer. Total cost depends on material, design complexity, mold, manufacturing process, quantity, plating, enamel, ribbon, packaging, and shipping.

Can zinc alloy medals be plated gold or silver?

Yes. Zinc alloy medals are commonly manufactured with decorative metallic finishes, including gold, silver, antique gold, antique silver, bronze, and other plating combinations. Zamak 3 is documented as having good finishing characteristics for plating and related treatments.

Can brass medals have enamel?

Yes. Brass medals can be combined with soft enamel, hard enamel, painted color areas, and various plating finishes.

Which material should I choose for a marathon medal?

For a detailed 3D marathon medal, zinc alloy is often an excellent starting point. It allows complex runners, city landmarks, race symbols, and irregular shapes to be incorporated into the design.

Which material should I choose for a military medal?

For a traditional, heavy commemorative design, brass can be a strong choice. If the design requires complex 3D sculpting, zinc alloy may offer greater manufacturing flexibility.

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Final Verdict

Zinc alloy and brass are both excellent materials for custom medals—but they solve different design problems.

Choose zinc alloy when your priority is:

3D detail + complex shapes + efficient die casting + flexible designs

Choose brass when your priority is:

higher density + substantial weight + traditional feel + premium positioning

For most modern sports and event medals with complex 3D artwork, zinc alloy is often the more versatile manufacturing choice.

For premium commemorative awards where weight and traditional metal character are important, brass deserves serious consideration.

The most professional approach is to evaluate the actual artwork, dimensions, thickness, quantity, finish, and manufacturing process together rather than selecting a material based on price alone.

About Custom Medal Manufacturing

Challenge Coin Badges is an OEM/ODM custom metal product manufacturer specializing in custom medals, challenge coins, military badges, lapel pins, cufflinks, and related metal products. The company has more than 20 years of custom metal manufacturing experience and a production team of more than 100 people.

For custom medal projects, customers can provide a logo, sketch, CAD file, reference image, or basic concept. The manufacturing team can then evaluate the appropriate material, dimensions, 2D/3D construction, plating, enamel, ribbon, and production method.

Website: www.challengecoinbadges.com
Email: sales@challengecoinbadges.com