How are custom medals actually made? From the first artwork file to the final packaged award, every stage affects the medal’s appearance, durability, production cost, and delivery time. This guide explains the complete custom medal manufacturing process, including design, mold making, die casting or stamping, polishing, plating, enamel, assembly, quality inspection, and packaging.
A custom medal may look simple when finished, but producing a professional-quality medal involves multiple manufacturing processes.
A typical custom medal can pass through:
Artwork → Engineering → Mold Making → Metal Forming → Trimming → Polishing → Plating → Enamel → Assembly → Quality Inspection → Packaging → Shipping
The exact process depends on the medal’s material, shape, thickness, size, artwork, quantity, and finishing requirements.
For sports competitions, marathons, schools, corporate awards, military ceremonies, charity events, and commemorative programs, understanding the manufacturing process can help buyers make better decisions about design, material, budget, quality, and lead time.
1. Step 1: Create the Medal Artwork
Every custom medal starts with an idea.
The customer may provide:
- AI, PDF, CDR, EPS, or SVG artwork
- Company or organization logo
- Hand-drawn sketch
- Photograph
- Existing medal reference
- Event information
- Sports symbol
- Military insignia
- Mascot
- Commemorative concept
The artwork should define the major visual elements, including:
- Medal shape
- Front design
- Back design
- Text
- Logo
- 2D or 3D elements
- Enamel colors
- Plating
- Ribbon
- Year
- Event information
Why artwork preparation matters
A design that looks good on a computer screen may not automatically work as a physical medal.
For example, extremely thin lines, tiny letters, narrow gaps, and very deep recesses may create manufacturing problems.
An experienced manufacturer should review the artwork before creating the production mold.
2. Step 2: Engineering and 3D Design
After artwork approval, the design is converted into a production-ready structure.
For a simple 2D medal, the engineering process may be relatively straightforward.
For a 3D medal, the manufacturer may need to create a detailed 3D model.
Engineers evaluate:
- Overall dimensions
- Medal thickness
- Relief height
- Recess depth
- Letter size
- Metal borders
- Enamel cavities
- Sharp corners
- Internal gaps
- Ribbon attachment
- Mold separation
- Casting requirements
This stage is particularly important for highly detailed medals.
A 70 mm medal with a simple logo and text requires very different engineering from a 70 mm medal featuring a sculpted athlete, building, animal, or military emblem.
3. Step 3: Digital Mockup and Customer Approval
Before making the final production mold, the manufacturer should provide a digital proof or 3D rendering.
A professional mockup allows the customer to check:
- Front artwork
- Back artwork
- Medal dimensions
- Text
- Logo proportions
- 3D relief
- Plating colors
- Enamel colors
- Ribbon design
This is one of the most important checkpoints in the entire manufacturing process.
Why?
Changing artwork before mold production is relatively easy.
Changing the design after the mold has been manufactured can require additional engineering or even a new mold.
For large orders, customers should carefully review the proof before giving final approval.
4. Step 4: Mold Making
Once the artwork is approved, the manufacturer creates the production mold.
The mold is one of the most important components in custom medal manufacturing because it determines the physical geometry of the medal.
Depending on the production method, manufacturers may use precision CNC machining, EDM, engraving, and other tooling processes.
For a detailed 3D medal, the mold must reproduce:
- Sculpted surfaces
- Raised elements
- Recessed areas
- Text
- Logos
- Borders
- Decorative patterns
2D vs 3D molds
A relatively simple 2D medal generally requires less complicated tooling.
A 3D medal may require much more engineering because the mold must accurately reproduce three-dimensional surfaces.
This is one reason why highly detailed 3D medals can have higher tooling costs.
5. Step 5: Metal Forming
Once the mold is ready, the metal body of the medal is produced.
The exact process depends on the selected material.
Zinc Alloy Die Casting
Zinc alloy is commonly used for complex custom medals because it is suitable for pressure die casting.
A simplified process is:
Melt zinc alloy → Inject molten alloy into mold → Cool → Open mold → Remove medal → Trim
Zinc alloys such as Zamak 3 have a melting range of approximately 381–387°C, making them suitable for die-casting applications.
This process works particularly well for:
- 3D medals
- Irregular shapes
- Sculpted figures
- Complex logos
- Deep relief
- Multi-level designs
Brass Stamping
Brass medals may be produced through stamping or other forming processes depending on the design.
The basic concept is:
Brass sheet → Stamping → Cutting → Forming → Polishing
Brass is particularly suitable for relatively flat or moderately detailed medal designs.
For premium commemorative medals, brass can provide a substantial weight and traditional metal feel.
6. Step 6: Trimming and Edge Processing
After die casting or stamping, excess metal may remain around the medal.
Manufacturers remove this material through trimming and related processes.
The edges are then processed to achieve:
- Correct dimensions
- Smooth edges
- Clean contours
- Consistent thickness
This stage is especially important for irregular-shaped medals.
A medal with a complicated outline may require additional edge processing compared with a standard round medal.
7. Step 7: Polishing
Polishing removes surface imperfections and prepares the medal for subsequent finishing.
Depending on the product, manufacturers may use:
- Tumbling
- Grinding
- Manual polishing
- Mechanical polishing
- Precision surface finishing
The goal is to create a clean surface before plating or enamel.
Polishing is particularly important when the final product requires:
Bright gold + bright silver + polished metal areas
because surface imperfections can become more visible after plating.
8. Step 8: Plating and Surface Finishing
After polishing, the medal can receive its final metallic appearance.
Common finishes include:
- Bright gold
- Bright silver
- Antique gold
- Antique silver
- Antique bronze
- Copper
- Black nickel
- Two-tone finishes
Bright Finish
A bright finish creates a cleaner and more reflective appearance.
It is often used for:
- Championship medals
- Premium sports awards
- Corporate awards
- Modern designs
Antique Finish
Antique plating intentionally creates darker recessed areas.
This makes raised details more visually prominent.
It is especially effective for:
- Military medals
- Police awards
- Historical commemorative medals
- 3D sculpted medals
- Traditional organizational awards
9. Step 9: Enamel Filling
If the medal includes color, enamel is added after the appropriate metal finishing stages.
Two common options are:
Soft Enamel
The enamel remains slightly below the metal surface.
Advantages include:
- Strong metal borders
- Textured appearance
- Cost efficiency
- Good suitability for sports medals
- Strong color separation
Hard Enamel
The enamel is filled and polished to create a smooth surface.
Advantages include:
- Flat surface
- Premium appearance
- Clean color areas
- Professional presentation
The choice depends on the medal’s application, artwork, budget, and desired appearance.
10. Step 10: Selective Polishing and Finishing
Some medals use multiple surface treatments.
For example:
Antique gold + polished raised details + recessed dark areas
This creates visual contrast without adding additional colors.
A complex medal may therefore go through several finishing stages.
For a 3D military medal, for example:
- Die casting
- Trimming
- Polishing
- Antique gold plating
- Selective polishing
- Protective finishing
The raised eagle, stars, or lettering can then stand out against darker recessed areas.
11. Step 11: Ribbon and Accessories
The medal itself is only one part of the finished award.
A complete event medal may include:
- Polyester ribbon
- Neck ribbon
- Custom printed ribbon
- Metal attachment
- Safety clip
- Presentation box
- Plastic bag
- Individual packaging
The ribbon can be customized with:
- Event name
- Logo
- Year
- Brand colors
- Sponsor information
- Pattern
For marathon and sports events, ribbon design can significantly increase the overall visual impact of the medal.
12. Step 12: Quality Inspection
Quality inspection should be performed before packaging.
Important inspection points include:
Dimensions
Check:
- Diameter
- Width
- Height
- Thickness
- Ribbon length
Surface
Inspect for:
- Scratches
- Pitting
- Uneven polishing
- Plating defects
- Surface contamination
Enamel
Check for:
- Missing color
- Overflow
- Incorrect color
- Bubbles
- Uneven filling
- Contamination
3D Details
Check:
- Sculpted relief
- Letter definition
- Logo clarity
- Border consistency
Assembly
Check:
- Ribbon attachment
- Ring
- Clasp
- Medal connection
For large production orders, quality control should use agreed samples or specifications as the reference standard.
13. Step 13: Sample Approval Before Mass Production
For large projects, a physical sample can be extremely valuable.
A customer can inspect:
- Actual weight
- Surface finish
- Enamel colors
- 3D relief
- Ribbon quality
- Plating
- Overall size
A digital rendering can show the concept, but a physical sample reveals details that a screen cannot fully reproduce.
This is particularly important for:
- 3D medals
- Large medals
- Multi-color enamel
- Two-tone plating
- Premium awards
- Complex logos
14. Step 14: Mass Production
After sample approval, the manufacturer begins mass production.
A typical large order may be divided into several production stages:
Metal production → Surface preparation → Plating → Enamel → Assembly → Inspection → Packaging
Production capacity depends on:
- Order quantity
- Number of molds
- Medal size
- Manufacturing method
- Enamel colors
- Finishing requirements
- Factory capacity
- Quality-control requirements
A professional manufacturer should provide a realistic production schedule rather than promising an unrealistically short lead time.
15. Step 15: Packaging
Packaging protects the medals during transportation and also influences the customer’s perception of the product.
Common packaging options include:
- Individual polybags
- Bubble protection
- Paper boxes
- Velvet boxes
- Presentation boxes
- Custom printed boxes
Budget Packaging
Suitable for:
- Large marathon orders
- School competitions
- Mass participation events
Premium Packaging
Suitable for:
- Corporate awards
- Military commemorative medals
- Anniversary medals
- Executive recognition
- Collector pieces
16. Step 16: Shipping
After final inspection and packaging, the medals are prepared for shipment.
International shipping options can include:
- Express
- Air freight
- Sea freight
- Courier services
The best method depends on:
- Quantity
- Destination
- Required delivery date
- Budget
- Package dimensions
For a large sports event, the delivery schedule should include sufficient time for customs clearance and local transportation.
Manufacturing Timeline
A custom medal project can generally be divided into several stages:
| Stage | Main Activity |
|---|---|
| 1 | Artwork preparation |
| 2 | Engineering review |
| 3 | Digital mockup |
| 4 | Customer approval |
| 5 | Mold production |
| 6 | Metal forming |
| 7 | Trimming |
| 8 | Polishing |
| 9 | Plating |
| 10 | Enamel filling |
| 11 | Assembly |
| 12 | Quality inspection |
| 13 | Packaging |
| 14 | Shipping |
The exact timeline varies according to design complexity, order quantity, production method, and factory workload.
For urgent projects, customers should communicate the event date before production begins.
What Determines Custom Medal Manufacturing Cost?
The final price is not determined by metal material alone.
A more useful cost model is:
Total Cost = Tooling + Metal + Manufacturing + Finishing + Enamel + Ribbon + Packaging + Shipping
Major cost factors include:
1. Medal Size
A 70 mm medal normally requires more material than a 50 mm medal.
2. Thickness
Increasing thickness increases material consumption and weight.
3. Material
Zinc alloy, brass, iron, and other materials have different costs and manufacturing requirements.
4. 2D vs 3D
Complex 3D designs generally require more engineering and tooling.
5. Enamel
More colors and more complicated enamel areas can increase finishing time.
6. Plating
A simple single finish is usually easier to manufacture than a complex multi-finish medal.
7. Quantity
Larger orders can distribute tooling costs across more pieces.
8. Packaging
A premium box can significantly increase the total project cost compared with a simple polybag.
Case Study: 5,000 Custom Marathon Medals
Consider a hypothetical marathon project requiring:
5,000 medals
Specifications:
- 65 mm diameter
- Zinc alloy
- 3 mm thickness
- 3D runner
- City skyline
- Event logo
- Three enamel colors
- Antique gold finish
- Custom neck ribbon
Design Stage
The organizer provides the marathon logo and city skyline.
The engineering team converts the artwork into a 3D production model.
Mold Stage
The 3D runner and skyline are integrated into the die-casting mold.
Production Stage
The medals are die cast, trimmed, polished, plated, and filled with enamel.
Assembly Stage
The medals are connected to custom printed ribbons.
Quality Stage
Samples are checked for:
- 3D definition
- Enamel consistency
- Plating
- Dimensions
- Ribbon attachment
Result
For a large marathon order, the combination of:
Zinc alloy + 3D relief + soft enamel + custom ribbon
can provide a good balance of visual impact, customization, production efficiency, and cost.
Case Study: Premium Corporate Anniversary Medal
A second hypothetical project involves:
500 corporate anniversary medals
Specifications:
- 60 mm diameter
- Brass
- Minimalist company logo
- Hard enamel
- Polished gold plating
- Presentation box
The goal is not simply to produce an inexpensive medal.
The product is intended to function as a premium employee recognition gift.
The manufacturing strategy therefore emphasizes:
material weight + polished surface + smooth enamel + premium packaging
In this application, the additional finishing cost can be justified by the higher perceived value of the award.
How to Reduce Manufacturing Costs Without Sacrificing Quality
There are several practical ways to control costs.
Keep the Medal Design Efficient
Avoid unnecessary micro-details that do not contribute to the visual effect.
Select the Right Material
Do not automatically choose brass for every medal.
For complex 3D designs, zinc alloy may provide a more efficient manufacturing solution.
Control the Size
A slightly smaller medal can reduce material consumption and shipping weight.
Use Enamel Strategically
Instead of filling every recessed area with color, combine:
metal relief + plating + selective enamel
to create contrast.
Optimize Quantity
If the event requires a large number of medals, request pricing based on the actual expected quantity.
Choose Appropriate Packaging
Do not use expensive presentation boxes for medals that will be distributed in large quantities unless the event requires them.
Common Manufacturing Problems and Their Causes
Problem 1: Blurry Small Text
Possible cause:
The lettering is too small for the selected manufacturing method.
Solution:
Increase letter size or use engraving/raised metal instead.
Problem 2: Uneven Enamel
Possible cause:
Incorrect filling or insufficient process control.
Solution:
Use production samples and establish an approved color/finish standard.
Problem 3: Plating Color Variation
Possible cause:
Differences in surface preparation, plating conditions, or batch processing.
Solution:
Use approved reference samples and consistent production parameters.
Problem 4: Weak 3D Relief
Possible cause:
The original artwork does not contain enough depth or the mold design is not properly engineered.
Solution:
Review the 3D model before mold production.
Problem 5: Scratches on Finished Medals
Possible cause:
Poor handling after polishing or plating.
Solution:
Improve protective handling, inspection, and packaging procedures.
How to Choose a Custom Medal Manufacturer
Do not compare suppliers based only on the lowest unit price.
Look for a manufacturer that can demonstrate:
- In-house engineering
- Professional mold making
- 2D and 3D manufacturing
- Die casting capability
- Brass stamping capability
- Enamel finishing
- Plating
- Ribbon production
- Quality inspection
- Sample approval
- OEM/ODM support
- International shipping experience
A manufacturer with multiple production capabilities can often recommend a manufacturing method based on the actual design rather than forcing every project into the same process.
FAQ
How long does it take to manufacture custom medals?
Production time depends on the artwork, tooling, material, quantity, enamel, plating, packaging, and factory schedule. Confirm the complete production and shipping timeline before placing an event order.
What is the first step in making a custom medal?
The first step is normally artwork preparation. The manufacturer then reviews the artwork for production feasibility and creates a digital or 3D proof.
Are custom medals die cast or stamped?
Both methods are used. Zinc alloy medals are commonly die cast, while brass medals can often be stamped or formed. The best process depends on the design and material.
Are zinc alloy medals suitable for 3D designs?
Yes. Zinc alloy is particularly suitable for complex 3D die-cast medals because the manufacturing process can reproduce detailed sculpted surfaces.
Are brass medals better than zinc alloy medals?
Not necessarily. Brass provides higher density and a substantial feel, while zinc alloy offers excellent flexibility for complex 3D designs. The correct material depends on the project.
Can I put a logo on both sides of a medal?
Yes. Both the front and back can be customized with logos, text, dates, symbols, or other artwork.
Can custom medals use both 2D and 3D elements?
Yes. Many medals combine a 3D centerpiece with 2D lettering, borders, logos, and enamel areas.
Can I choose the ribbon color?
Yes. Custom ribbons can usually be produced in specific colors and can include logos, event names, dates, patterns, or sponsor information.
Can I approve a sample before mass production?
Yes, and for large or complex orders, physical sample approval is strongly recommended.
What file format should I send for custom medal artwork?
Vector formats such as AI, EPS, SVG, CDR, or PDF are generally useful because they allow the manufacturer to inspect and modify artwork accurately. If you only have a JPG, PNG, photograph, or sketch, the manufacturer may be able to recreate the artwork.
What is the difference between soft enamel and hard enamel?
Soft enamel remains slightly recessed between raised metal borders, while hard enamel is filled and polished to create a smoother, flatter surface.
Can medals have multiple plating finishes?
Yes. Depending on the design and manufacturing process, a medal can combine different metallic effects or use selective polishing to create contrast.
Final Checklist Before Production
Before approving your custom medal, confirm:
- Medal size
- Thickness
- Material
- Front artwork
- Back artwork
- 2D/3D details
- Enamel type
- Enamel colors
- Plating finish
- Ribbon design
- Ribbon length
- Packaging
- Quantity
- Sample approval
- Production schedule
- Shipping deadline
Getting these details confirmed before mold production can reduce misunderstandings and minimize costly changes later.
Final Thoughts
Custom medal manufacturing is a combination of design, engineering, metalworking, surface finishing, enamel, assembly, and quality control.
A successful medal is not simply a piece of metal with a logo.
The best results come from matching the manufacturing process to the purpose of the award.
For example:
Large marathon → zinc alloy + 3D relief + soft enamel + custom ribbon
Premium corporate award → brass + polished finish + hard enamel + presentation box
Military commemorative medal → detailed relief + antique finish + selective polishing
School sports medal → zinc alloy + colorful enamel + economical packaging
The right combination can improve the medal’s appearance while keeping production practical and cost-effective.
Custom Medal Manufacturing by Challenge Coin Badges
Challenge Coin Badges is an OEM and ODM custom metal product manufacturer specializing in custom medals, challenge coins, military badges, police badges, lapel pins, cufflinks, and other metal recognition products.
With 20+ years of custom metal manufacturing experience and a team of 100+ people, the company supports projects from artwork review and engineering through mold making, die casting, stamping, polishing, plating, enamel, assembly, inspection, and packaging.
Whether you need sports medals, marathon medals, school awards, corporate recognition medals, military commemorative medals, or custom event medals, the manufacturing team can evaluate your design and recommend an appropriate production process.
Website: www.challengecoinbadges.com
Email: sales@challengecoinbadges.com