When ordering custom medals, one of the earliest manufacturing decisions is choosing the right metal.
Two commonly considered options are brass and zinc alloy. Both can produce attractive custom medals, but they have different characteristics in terms of weight, detail, manufacturing methods, design flexibility and cost.
The right choice depends on the type of medal you are producing, the artwork, quantity, budget and how you want the finished award to look and feel.
This guide compares brass and zinc alloy medals to help you select the more suitable material for your project.
Brass vs Zinc Alloy Medals at a Glance
| Feature | Brass Medals | Zinc Alloy Medals |
|---|---|---|
| Metal feel | Dense and solid | Solid with flexible design options |
| Typical manufacturing | Stamping / forming | Die casting |
| Fine 2D details | Excellent | Excellent |
| Complex 3D relief | Good | Excellent |
| Custom shapes | Good | Excellent |
| Cutouts | Possible | Highly suitable |
| Multi-level designs | Possible | Highly suitable |
| Enamel | Soft or hard enamel | Soft or hard enamel |
| Plating options | Wide range | Wide range |
| Large complex designs | More demanding | Very suitable |
| Premium appearance | Excellent | Excellent |
| Design flexibility | High | Very high |
| Best for | Traditional and premium medals | Complex and highly customized medals |
The final result depends on the specific design and manufacturing process, so these characteristics should be treated as project guidelines rather than absolute rules.
1. What Is Brass?
Brass is a copper-based alloy commonly used for metal products, awards and decorative items.
It has a dense, traditional metal feel and can be used for detailed custom medals.
Brass medals can be produced using processes such as stamping, forming and other machining or finishing methods depending on the design.
Brass is particularly attractive when the medal requires a classic metal appearance.
Brass medals can be suitable for:
- Corporate awards
- Commemorative medals
- Traditional sports medals
- Military-style recognition products
- Premium awards
- Detailed logo medals
2. What Is Zinc Alloy?
Zinc alloy is a metal alloy commonly used for die-cast custom products.
One of its major advantages is its ability to reproduce complicated shapes and relief details.
Zinc alloy can be particularly useful when the medal contains:
- 3D relief
- Multiple levels
- Custom silhouettes
- Cutouts
- Large raised areas
- Sculptural artwork
- Complex borders
This makes zinc alloy a popular option for highly customized sports medals.
3. Manufacturing Process Differences
One of the biggest differences between brass and zinc alloy is the way they are commonly manufactured.
Brass
Brass medals are often produced through stamping or forming processes.
The artwork is transferred to a die, and the metal is formed into the desired design.
This approach works particularly well for designs based around:
- Clear outlines
- Text
- Logos
- Flat relief
- Traditional medal shapes
Zinc Alloy
Zinc alloy medals are commonly produced through die casting.
Molten zinc alloy is injected into a custom mold, allowing the material to reproduce complex shapes and relief.
This is particularly useful for:
- 3D medals
- Irregular shapes
- Deep relief
- Multi-level designs
- Cutouts
- Complex structures
4. Which Material Is Better for 3D Medals?
For highly detailed 3D medals, zinc alloy is often the more flexible choice.
A 3D design may contain:
- Raised athletes
- Sports equipment
- Animals
- Buildings
- Faces
- Logos
- Sculptural elements
Zinc alloy die casting can reproduce these types of shapes effectively when the tooling is properly engineered.
Brass can also be used for relief designs, but the manufacturing method needs to be selected according to the required depth and complexity.
Recommendation
For a highly sculptural custom medal:
Zinc alloy → strong choice
For a traditional relief medal:
Brass → strong choice
5. Which Material Is Better for 2D Medals?
Both materials can work well for 2D designs.
A 2D medal may include:
- Event logo
- Race name
- Year
- Simple sports symbol
- Text
- Decorative border
If the artwork is relatively flat and traditional, brass can provide a classic appearance.
If the 2D design includes unusual shapes or additional dimensional features, zinc alloy may provide more design flexibility.
6. Which Material Provides More Design Freedom?
In general, zinc alloy offers greater freedom for complex shapes.
It can be used for designs such as:
- Star-shaped medals
- Animal-shaped medals
- Athlete silhouettes
- Stadium-shaped medals
- Multi-layer designs
- Cutout medals
- Large 3D structures
Brass is also highly customizable, but certain complex geometries may require more careful engineering.
If your medal has an unusual silhouette, ask the manufacturer to review the artwork before selecting the material.
7. Which Material Is Heavier?
Brass has a relatively dense metal feel.
This can give a medal a substantial and premium impression.
Zinc alloy medals can also be made substantial, particularly when the design is thick or large, but the final weight depends on:
- Material
- Size
- Thickness
- Internal structure
- Cutouts
Therefore, it is not accurate to select a material based only on the expected weight.
If weight is important, ask the manufacturer to estimate the finished medal weight based on the actual dimensions.
8. Which Material Feels More Premium?
Both can produce premium-looking medals.
The perceived quality of a medal depends on much more than the base metal.
Important factors include:
- Medal thickness
- Surface preparation
- Plating
- Relief
- Enamel
- Polishing
- Edge finishing
- Ribbon
- Packaging
A well-designed zinc alloy medal with excellent plating and finishing can look more premium than a poorly finished brass medal.
The manufacturing quality matters as much as the material selection.
9. Brass and Zinc Alloy Plating Options
Both materials can be finished with a wide range of plating options.
Common finishes include:
- Bright gold
- Antique gold
- Bright silver
- Antique silver
- Bronze
- Antique bronze
- Copper
- Black nickel
Bright Finish
Creates a cleaner and more reflective appearance.
Antique Finish
Creates contrast between raised and recessed areas.
For highly detailed 3D medals, antique finishes can be particularly effective because they help emphasize the relief.
10. Brass vs Zinc Alloy for Enamel
Both materials can be combined with enamel.
Soft Enamel
Soft enamel remains slightly recessed within the metal borders.
It works well for:
- Sports logos
- School medals
- Event colors
- Charity medals
Hard Enamel
Hard enamel is polished to create a smooth surface.
It can be appropriate for:
- Corporate awards
- Premium medals
- Championship medals
- Commemorative products
The enamel process is generally determined by the artwork and design rather than the base metal alone.
11. Which Is Better for Complex Shapes?
For highly irregular shapes, zinc alloy is often advantageous.
Examples include:
Runner-Shaped Medal
The outline follows the body of an athlete.
Soccer Ball Medal
The medal uses a three-dimensional ball structure.
Animal Medal
The medal follows an animal silhouette.
Stadium Medal
Architectural elements are incorporated into the medal.
Cutout Medal
Specific sections are removed from the metal body.
These designs can benefit from zinc alloy die casting.
12. Which Is Better for Traditional Medals?
Brass can be a strong choice for traditional designs.
Examples include:
- Round medals
- Shield medals
- Logo medals
- Commemorative medals
- Classic award medals
If the design emphasizes a traditional metal appearance rather than complicated 3D geometry, brass can be an excellent option.
13. Cost Considerations
Material price is only one part of the final medal cost.
The total cost can also depend on:
- Quantity
- Size
- Thickness
- Tooling
- Artwork complexity
- 2D or 3D production
- Plating
- Enamel
- Ribbon
- Packaging
- Shipping
Therefore, you should not assume that one material will always be cheaper.
A manufacturer should quote the actual project according to its complete specifications.
A useful comparison is:
Same quantity + same size + same thickness + same finish + same ribbon + same packaging
Then compare the total quotation.
14. Brass vs Zinc Alloy for Large Medals
Large medals require additional consideration.
A large medal may become heavy if the thickness is increased too much.
Zinc alloy can be useful for large custom designs because the manufacturer can incorporate:
- Cutouts
- Recessed sections
- Multiple levels
- Complex shapes
These design features can help create a visually impressive large medal without simply making the entire piece extremely thick.
Brass can also be used for larger medals, but the final weight and manufacturing method should be evaluated carefully.
15. Brass vs Zinc Alloy for Sports Medals
Sports medals are one of the most common applications for custom medal manufacturing.
Running and Marathon
Zinc alloy is useful for:
- Large marathon medals
- 3D runners
- City-shaped medals
- Complex race logos
Brass is suitable for:
- Classic running medals
- Flat logos
- Traditional award designs
Soccer
Zinc alloy can work well for:
- 3D soccer balls
- Player designs
- Stadium shapes
- Multi-level artwork
Brass can work well for:
- Team logos
- Tournament names
- Traditional championship medals
School Sports
Both materials can work.
The decision can be based on:
- Quantity
- Budget
- Design complexity
- Desired weight
- Finish
16. Brass vs Zinc Alloy for Corporate Awards
Corporate awards often prioritize a professional and premium appearance.
Brass can provide a traditional, substantial feel.
Zinc alloy can provide greater freedom for:
- Company logos
- Custom shapes
- 3D branding
- Complex corporate symbols
For a premium corporate medal, the final plating and packaging may have a greater effect on perceived quality than the choice between the two metals.
17. Brass vs Zinc Alloy for Commemorative Medals
Commemorative medals often contain detailed historical information, logos, dates and symbols.
Brass can be a good choice for traditional commemorative designs.
Zinc alloy may be preferable when the design contains complex relief or unusual shapes.
For example:
Historical portrait + text + traditional border
→ Brass can be suitable.
3D building + landscape + multiple relief levels
→ Zinc alloy can be advantageous.
18. Brass vs Zinc Alloy for Custom 3D Medals
If your main priority is 3D detail, zinc alloy deserves serious consideration.
The die-casting process can support complex relief and sculptural elements.
However, 3D quality still depends on:
- Engineering
- Tooling
- Relief depth
- Surface preparation
- Polishing
- Plating
Simply choosing zinc alloy does not guarantee a good 3D medal.
The manufacturer’s engineering capability is equally important.
19. How to Choose Based on Your Design
Use this simple guide.
Choose Brass When:
- You want a traditional metal appearance.
- Your design is mainly 2D or shallow relief.
- You prefer a dense, substantial metal feel.
- Your design is based around stamping or traditional medal construction.
- You want a classic commemorative appearance.
Choose Zinc Alloy When:
- Your design has complex 3D relief.
- You need an unusual shape.
- Your medal contains cutouts.
- You need multiple levels.
- Your design is highly sculptural.
- You want maximum shape flexibility.
Consider Both When:
- The artwork is relatively simple.
- Both materials can meet the required specifications.
- You are primarily comparing cost and final appearance.
In these cases, ask the manufacturer to provide quotations for both materials.
20. Don’t Choose the Material Before Reviewing the Artwork
A common mistake is deciding:
“I want brass.”
or:
“I want zinc alloy.”
before the manufacturer has reviewed the design.
A better process is:
Artwork
↓
Engineering Review
↓
Material Recommendation
↓
Cost Comparison
↓
Final Material Selection
This approach allows the manufacturing method to match the actual product requirements.
21. Questions to Ask Your Manufacturer
Before ordering, ask:
- Which material is better for my artwork?
- Can this design be produced in both brass and zinc alloy?
- What is the estimated finished weight?
- What manufacturing method will be used?
- How deep can the relief be?
- What plating options are available?
- Can the medal use soft or hard enamel?
- What is the tooling cost?
- What is the MOQ?
- What is the production lead time?
- Can you provide a digital proof?
- Can you produce a physical sample?
- What packaging options are available?
The answers should be based on your actual artwork rather than generic product specifications.
22. Brass vs Zinc Alloy: Final Comparison
If your project requires a traditional, dense and classic medal, brass can be an excellent choice.
If your project requires complex 3D relief, unusual shapes or highly customized structures, zinc alloy can offer greater flexibility.
However, the material alone does not determine the quality of the finished medal.
The final result depends on:
Material + Engineering + Tooling + Metal Forming + Polishing + Plating + Enamel + Quality Control
A well-engineered medal made from the appropriate material will generally produce a better result than simply choosing a material based on price.
Custom Brass and Zinc Alloy Medal Manufacturing
ChallengeCoinBadges Official Website
ChallengeCoinBadges provides custom metal manufacturing for sports medals, award medals, commemorative medals and other customized recognition products.
Custom medal projects can be developed according to:
- Brass or zinc alloy material
- Custom dimensions
- Custom thickness
- 2D artwork
- 3D relief
- Soft enamel
- Hard enamel
- Bright plating
- Antique plating
- Custom shapes
- Custom ribbons
- Custom packaging
The manufacturing team can review your artwork and recommend a suitable production method based on the design, quantity, finish and budget.
For a custom medal quotation:
Website: www.challengecoinbadges.com
Email: sales@challengecoinbadges.com
When requesting a quotation, provide your artwork, quantity, medal size, thickness, preferred material, finish, ribbon requirements and delivery date.
Frequently Asked Questions
Is brass better than zinc alloy for medals?
Neither material is universally better. Brass can be excellent for traditional and substantial designs, while zinc alloy is often more flexible for complex 3D and custom-shaped medals.
Are zinc alloy medals durable?
Yes. When properly manufactured and finished, zinc alloy can be used for durable custom medals.
Are brass medals heavier?
Brass has a dense metal feel, but actual medal weight depends on size, thickness, design structure and whether the medal contains cutouts.
Can zinc alloy medals be 3D?
Yes. Zinc alloy die casting is well suited to many 3D medal designs.
Can brass medals have enamel?
Yes. Brass medals can be combined with soft enamel or hard enamel depending on the design.
Can zinc alloy medals have antique finishes?
Yes. Zinc alloy medals can be finished with options such as antique gold, antique silver, antique bronze and other plating treatments.
Which material is cheaper?
There is no universal answer. The final cost depends on material, quantity, dimensions, tooling, finishing, enamel, ribbon and packaging.
Which material is better for marathon medals?
Both can work. Zinc alloy is particularly useful for large, complex and 3D marathon medals, while brass can be suitable for traditional designs.
Which material is better for corporate medals?
Both can provide a premium appearance. The choice should depend on the design, desired weight, relief, finish and budget.
Can I get quotations for both materials?
Yes. Comparing brass and zinc alloy using the same size, thickness, quantity and finish is one of the best ways to determine which option fits your project.
Conclusion
Brass and zinc alloy can both produce high-quality custom medals, but they offer different manufacturing advantages.
Brass is a strong option for traditional, dense and classic medal designs.
Zinc alloy is a strong option for complex 3D relief, custom silhouettes, cutouts and highly detailed designs.
The best choice should be based on the actual artwork, application, quantity, desired appearance and budget.
If you are unsure which material to use, send the artwork to the manufacturer before making the final decision. An experienced production team can evaluate the design and recommend the material and manufacturing method that best fits the project.
For custom brass or zinc alloy medals: