A custom medal with cutout can create a much more distinctive appearance than a traditional solid medal.
Instead of filling the entire medal with metal, selected areas are removed to create negative space. This technique can make a medal lighter, more visually interesting, and closely connected to the event’s theme.
Cutout medals are widely suitable for:
- Running events
- Marathons
- Cycling races
- Swimming competitions
- Boxing tournaments
- Soccer championships
- School sports
- Police recognition
- Firefighter awards
- Military commemorative medals
- Corporate awards
- Anniversary events
However, cutout medals require more careful engineering than simple round medals. The shape, remaining metal structure, cutout size, thickness, finishing, and ribbon attachment all need to work together.
What Is a Cutout Medal?
A cutout medal contains one or more open areas where metal has been intentionally removed.
For example, a medal could feature:
- A runner-shaped opening
- A heart-shaped center
- A city skyline
- A soccer ball
- A star
- An organization logo
- A number
- A letter
- An animal silhouette
The open areas create negative space, allowing the background to become part of the visual design.
Why Choose a Cutout Medal?
A traditional medal may look like:
Solid metal + raised artwork
A cutout medal can look like:
Metal frame + open space + raised artwork
This can produce a lighter and more modern appearance.
Major advantages include:
- Unique visual identity
- More creative shapes
- Reduced metal in selected areas
- Strong negative-space effect
- Better integration with silhouettes
- Potentially lower weight
- Strong branding opportunities
Cutout Medal Design Ideas
1. Runner Cutout
A marathon medal could use a running athlete as the central negative space.
For example:
70 mm circular medal
with:
runner silhouette + city skyline + race year
This immediately communicates the event’s purpose.
2. Heart-Shaped Cutout
A heart can work well for:
- Charity runs
- Valentine’s events
- Hospital fundraising
- Community events
- Awareness campaigns
The heart can be integrated into the medal rather than simply printed on its surface.
3. Soccer Cutout
A soccer medal can incorporate:
- Ball-shaped opening
- Goal net
- Player silhouette
- Stadium outline
This creates a strong sports identity.
4. Boxing Glove Cutout
A boxing championship medal could feature a glove-shaped opening surrounded by:
- Championship text
- Laurel leaves
- Boxing ring ropes
- Event year
The result can be more visually dynamic than a conventional circular medal.
5. Firefighter Cutout
Firefighter medals can use:
- Maltese cross
- Fire helmet
- Axe
- Ladder
- Fire truck
A cutout Maltese cross or helmet can create a strong visual focal point.
6. Police Shield Cutout
A police recognition medal could use the shield itself as the outer silhouette or create a shield-shaped opening in the center.
Additional elements may include:
- Eagle
- Star
- Department initials
- Service year
7. City Skyline Cutout
For a city marathon or tourism event, the skyline can become the cutout.
For example:
Los Angeles skyline + race logo + 26.2
The skyline becomes instantly recognizable while maintaining a strong medal structure.
Cutout vs Solid Medal
| Feature | Cutout Medal | Solid Medal |
|---|---|---|
| Visual style | Modern/creative | Traditional |
| Negative space | Yes | No |
| Design flexibility | High | High |
| Weight | Potentially lower | Usually higher |
| Structural engineering | More demanding | Simpler |
| Suitable for silhouettes | Excellent | Good |
| 3D relief | Possible | Possible |
| Production complexity | Medium–High | Low–Medium |
| Premium appearance | Depends on design | Depends on design |
A cutout is not automatically better. It is a design choice.
How Cutouts Affect Medal Strength
One of the most important manufacturing considerations is structural strength.
If too much metal is removed, the remaining sections can become narrow.
For example, imagine a medal shaped like a:
runner silhouette
If the legs, arms, or surrounding frame are extremely thin, the medal may become structurally weak.
The manufacturer may recommend:
- Increasing metal width
- Simplifying the cutout
- Connecting isolated sections
- Increasing thickness
- Adjusting the outer frame
The objective is to maintain the original concept while creating a practical manufacturing structure.
Cutout Size Matters
Very small openings can be difficult to manufacture and finish.
Very large openings can weaken the medal.
The ideal design depends on:
- Medal size
- Thickness
- Material
- Manufacturing method
- Shape
- Number of cutouts
For this reason, the cutout should be evaluated during the engineering stage rather than after the mold has already been produced.
Cutout and Medal Thickness
Thickness and cutout design are closely connected.
Consider two hypothetical medals:
Medal A
70 mm diameter × 3 mm
Medal B
70 mm diameter × 5 mm
If both have the same cutout design, the thicker version generally provides a more substantial structure.
But thickness also increases:
- Weight
- Material usage
- Shipping cost
- Potential packaging size
Therefore, simply increasing thickness is not always the best solution.
Cutout and 3D Relief
A cutout medal can also include 3D elements.
For example:
Outer frame + open center + raised 3D runner
This creates several levels of visual depth.
A possible construction could include:
- Raised outer border
- Recessed background
- 3D central figure
- Open cutout area
This type of design requires careful mold engineering.
Cutout and Enamel
Cutout medals can also use enamel.
For example:
Blue enamel + gold plating + open center
or:
Red enamel + antique silver + custom cutout
The manufacturer needs to ensure that the remaining metal boundaries are sufficient to separate enamel areas.
Cutout Medal Materials
Common materials may include:
Zinc Alloy
Useful for:
- Complex shapes
- 3D designs
- Larger medals
- Detailed cutouts
Brass
Useful for:
- Stamped medals
- Traditional designs
- Crisp lettering
- Premium metal appearance
Copper
Can be suitable for certain specialty medals and traditional metalwork.
The best material depends on:
- Design
- Thickness
- Quantity
- Production process
- Required finish
Manufacturing Methods for Cutout Medals
Different designs may require different processes.
Die Casting
Often suitable for:
- Complex 3D shapes
- Irregular outlines
- Detailed cutouts
- Zinc alloy medals
Stamping
Can be suitable for:
- Brass medals
- Copper medals
- Simpler relief
- Traditional designs
Cutting
Depending on the design and production method, additional cutting or machining processes may be considered.
The manufacturer should determine the most appropriate process after reviewing the artwork.
Artwork Requirements for Cutout Medals
When preparing artwork, clearly indicate:
- Outer medal boundary
- Cutout areas
- Front artwork
- Back artwork
- Medal diameter
- Thickness
- 2D or 3D requirements
- Plating
- Enamel
- Ribbon hole
For example:
Outer diameter: 70 mm
Thickness: 4 mm
Central cutout: runner silhouette
Finish: antique gold
Enamel: red and blue
This gives the engineering team a much clearer starting point.
Use Vector Artwork
Vector artwork is strongly recommended for complex cutout designs.
Useful formats include:
- AI
- EPS
- SVG
- Vector PDF
The manufacturer needs to clearly distinguish:
metal
from:
open space
A vector file makes these boundaries easier to identify.
Avoid Extremely Narrow Bridges
One of the most common problems with cutout designs is a very narrow connecting section.
For example:
A medal shaped like a bicycle may have thin connections around the wheels.
These areas may need to be strengthened.
The manufacturer may suggest:
- Enlarging the connecting sections
- Simplifying the wheel design
- Increasing thickness
- Changing the outer frame
This is normal engineering optimization.
Cutout Medal With a Border
A border can improve structural stability.
For example:
70 mm medal
with:
4 mm outer frame
and a:
central cutout
The outer frame can help maintain overall rigidity while creating the desired negative-space effect.
A border can also provide space for:
- Event name
- Year
- Organization
- Laurel leaves
- Decorative lines
Double-Sided Cutout Medals
Cutout medals can have different front and back designs.
For example:
Front
Runner cutout + event logo
Back
26.2 MILES + 2026 + organizer
However, the back design should be considered together with the open areas.
The manufacturer needs to make sure the reverse-side artwork does not conflict with:
- Structural sections
- Relief
- Enamel
- Cutout edges
Cutout Medal With Custom Ribbon
The ribbon remains an important part of the overall design.
For example:
70 mm cutout medal + 32 mm custom ribbon
The ribbon can feature:
- Event logo
- Sponsor
- Event colors
- Year
- City
A cutout medal with a well-designed ribbon can create a complete event identity.
Packaging Considerations
Cutout medals can have unusual shapes.
This may affect:
- Individual bags
- Foam inserts
- Presentation boxes
- Carton packing
A custom-shaped medal may need a larger or specially shaped insert than a standard round medal.
For premium awards, a fitted presentation box can hold the medal securely.
Cutout Medals and Shipping Weight
Cutouts remove metal from the medal.
This can potentially reduce the weight compared with a similar solid design.
For example, a hypothetical:
70 mm × 4 mm solid medal
may use more metal than a:
70 mm × 4 mm medal with a large central cutout.
However, the final weight depends on the actual geometry.
For large-volume orders, even small differences can matter.
Hypothetical Weight Analysis
Suppose an event orders:
10,000 medals
and the cutout design reduces average medal weight by a hypothetical:
15 g
Then:
10,000 × 15 g = 150,000 g
or:
150 kg
of total medal weight reduction.
This is an illustrative calculation rather than a manufacturing specification.
It demonstrates why design geometry can affect logistics.
Case Study: Custom Marathon Cutout Medal
Consider a hypothetical marathon:
5,000 participants
The organizer wants:
70 mm custom medal
Design:
- Runner silhouette
- City skyline
- 26.2 miles
- 2026
- Gold plating
- Blue enamel
- 32 mm ribbon
The original design uses a completely solid background.
The manufacturer proposes replacing part of the background with a skyline cutout.
Result
The design becomes:
- More distinctive
- Visually lighter
- More recognizable
- Potentially lower in weight
The engineer also strengthens the runner and outer frame to maintain structural integrity.
This is an example of how manufacturing input can improve an original concept without changing the event’s core identity.
Case Study: Firefighter Recognition Medal
A fire department wants a commemorative medal for its:
50th anniversary
Design elements:
- Maltese cross
- Fire helmet
- 1976–2026
- Department initials
- Custom ribbon
The manufacturer creates a Maltese-cross cutout surrounded by a raised circular border.
The final design combines:
Cutout + 3D relief + antique finish
The result provides strong visual depth while keeping the medal connected to the department’s identity.
Case Study: Boxing Championship Medal
A boxing tournament orders:
1,000 championship medals
The proposed design includes:
- Boxing glove
- Championship belt
- Tournament name
- 2026
- Gold finish
A glove-shaped cutout is incorporated into the center.
The manufacturer adjusts the surrounding metal structure to prevent excessively thin sections.
The final medal combines:
3D boxing glove + cutout + custom enamel + championship ribbon.
This creates a more distinctive award than a standard circular medal.
Cutout Medal Cost Factors
Cutout design can influence pricing depending on:
- Medal size
- Thickness
- Material
- Number of cutouts
- 3D complexity
- Mold complexity
- Production method
- Enamel
- Plating
- Quantity
- Packaging
A cutout does not automatically mean a cheaper medal.
Some cutout designs can actually increase engineering and tooling complexity.
How to Reduce Cutout Medal Costs
Simplify the Cutout
Avoid unnecessary micro-details.
Optimize the Outer Shape
A complex contour can increase engineering requirements.
Use Moderate Thickness
Don’t increase thickness unless the design needs it.
Limit Excessive 3D Relief
Focus 3D detail on important visual elements.
Choose Efficient Packaging
A lightweight medal does not necessarily need a heavy presentation box.
Order Larger Quantities
Tooling costs are spread across more pieces when quantities increase.
Questions to Ask a Cutout Medal Manufacturer
Before approving production, ask:
- Is the cutout structurally strong enough?
- What thickness do you recommend?
- Which material is best?
- Can the design support 3D relief?
- Can enamel be added around the cutout?
- Will the cutout increase tooling costs?
- What will the approximate finished weight be?
- Can you provide a 3D digital proof?
- Can you make a physical sample?
- What packaging is recommended?
Cutout Medal Quality Checklist
Before mass production, check:
- Outer shape
- Cutout shape
- Structural bridges
- Medal thickness
- Relief
- Text
- Logo
- Plating
- Enamel
- Ribbon hole
- Ribbon
- Approximate weight
- Packaging
- Physical sample
- Final production approval
Final Thoughts
A custom medal with cutout is an excellent choice when you want something more distinctive than a traditional solid medal.
The most successful designs balance:
Creativity + structural strength + manufacturability + cost + presentation.
The most important point is that a cutout should not simply be added because it looks interesting in a digital design.
The manufacturer should evaluate:
cutout size + remaining metal + thickness + material + relief + finishing
before the mold is produced.
Whether you are creating a marathon medal, boxing medal, firefighter medal, police medal, military medal, school sports medal, or corporate award, a properly engineered cutout can turn a standard medal into a memorable piece of recognition.
Custom Cutout Medal Manufacturing
ChallengeCoinBadges provides custom medal manufacturing for sports events, marathons, boxing competitions, police organizations, firefighter departments, military organizations, schools, corporations, and commemorative programs.
The production team can review custom artwork, medal dimensions, cutout requirements, 2D/3D designs, plating, enamel, ribbons, and packaging.