From Artwork and Mold Engineering to Die Casting, Polishing, Plating, Enamel, Ribbon Assembly and Final Quality Control

A custom medal may look like a relatively simple metal product, but producing a professional medal involves a series of interconnected manufacturing processes.

The final appearance is determined long before the medal reaches the polishing or plating department. Artwork, mold engineering, metal selection, casting or stamping, surface preparation, plating, coloring, assembly and quality control all influence the final result.

For buyers of marathon medals, sports awards, military medals, corporate recognition medals and commemorative medals, understanding the manufacturing process can also help control cost, production time and quality.

Current manufacturer process documentation shows a typical custom medal workflow of design → mold making → casting/stamping → deburring and polishing → plating → coloring → ribbon/assembly → inspection → packaging.

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Custom Medal Manufacturing at a Glance

A typical custom medal can pass through 8–12 major production stages, depending on the design.

Basic Manufacturing Flow

Artwork → 3D Engineering → Mold Making → Die Casting/Stamping → Deburring → Polishing → Plating → Enamel/Printing → Ribbon Assembly → QC → Packaging

Not every medal requires every process.

For example:

• A simple die-struck medal may not require complex 3D casting.
• A 3D zinc alloy medal requires more extensive mold engineering.
• A soft enamel medal requires color filling.
• A premium commemorative medal may require multiple plating processes.
• A marathon medal usually requires ribbon assembly.
• A medal with variable names may require laser engraving.

The manufacturing process should therefore be designed around the application and artwork, rather than forcing every medal through exactly the same production route.

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1. Artwork Design and Engineering

Everything starts with the artwork.

The customer may provide:

• AI/EPS vector artwork
• PDF
• Logo
• Sketch
• Photograph
• Existing medal
• Hand-drawn concept
• Reference image

The manufacturer then converts the artwork into a production-ready design.

This stage determines:

• Medal diameter
• Thickness
• Shape
• Raised areas
• Recessed areas
• 2D or 3D relief
• Enamel areas
• Plating
• Text size
• Ribbon attachment
• Cut-outs

A production drawing should ideally specify the dimensions, colors, plating, ribbon and other important specifications before mold production begins.

Why artwork engineering matters

A design that looks perfect on a computer screen may not work at 50–60 mm in real metal.

For example, very small text can become difficult to read after casting and plating.

A professional manufacturer should therefore review the artwork before making the mold.

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2. 2D or 3D Engineering

This is one of the most important decisions.

2D Medal

A 2D medal generally uses:

• Flat metal surfaces
• Raised outlines
• Recessed areas
• Simple logos
• Text

It is suitable for:

• School awards
• Basic sports medals
• Corporate recognition
• Simple commemorative products

3D Medal

A 3D medal uses different relief levels to create greater depth.

It is particularly useful for:

• Human figures
• Animals
• Buildings
• Cars
• Aircraft
• Sports scenes
• Detailed logos
• Character designs

3D designs normally require more complex mold engineering.

One current manufacturer describes its zinc-alloy production as using CNC-machined steel molds and high-pressure die casting to reproduce 3D relief and cut-out structures.

Data Point

One published 2026 manufacturer price table gives an indicative range of approximately:

• 2.5″ zinc alloy medal, 500 pcs: $2.20–$3.50
• 3D medal, 500 pcs: $3.80–$5.80
• Spinning medal, 500 pcs: $4.50–$6.80

These are supplier-specific market examples rather than universal industry prices, but they illustrate how additional mechanical and design complexity can increase manufacturing cost.

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3. Mold Making

Once the design is approved, the manufacturer creates the production mold.

For die-cast medals, the mold is generally made from hardened tool steel.

A typical process includes:

CAD/3D Model → CNC Machining → Detail Engraving → Heat Treatment → Mold Polishing → Inspection

One current manufacturing guide states that standard medal molds may take approximately 5–7 days, while complex 3D designs or multi-piece molds may require longer.

Another detailed production description explains that mold steel can undergo CNC machining, surface texturing and heat treatment to improve durability during repeated production.

Why the mold is so important

The mold determines:

• Relief sharpness
• Text definition
• Edge quality
• Surface texture
• Dimensional consistency

A poor mold can create problems that become difficult to correct later.

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4. Die Casting or Stamping

The next stage depends on the material and manufacturing method.

Zinc Alloy Die Casting

For zinc alloy medals, molten alloy is injected into the mold under high pressure.

This method is particularly useful for:

• 3D medals
• Complex shapes
• Cut-out medals
• Deep relief
• Detailed logos

One current manufacturer reports using zinc alloy at approximately 385°C and an 88-ton die-casting machine, with individual shot cycles of approximately 15–30 seconds. These figures are manufacturer-specific operating data, not universal requirements for every factory or medal.

Production calculation example

If one die-casting cycle produces multiple pieces and the effective cycle is 20 seconds, the theoretical machine-cycle rate is:

3 cycles/minute

or approximately:

180 cycles/hour

Actual output will be lower once you account for:

• Loading
• Cooling
• Trimming
• Machine adjustments
• Mold maintenance
• Rejects
• Worker handling

This is why theoretical machine speed should never be confused with actual daily production capacity.

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5. Stamping / Die Striking

Brass, copper and iron medals can also be produced through stamping or die striking.

The process generally involves:

Metal Sheet → Die → High Pressure → Formed Medal → Trimming → Finishing

Die-struck medals are often selected for:

• Traditional awards
• Military-style medals
• Corporate recognition
• Premium flat designs
• Fine lettering

Current manufacturer documentation distinguishes zinc alloy die casting from brass, copper and iron stamping/striking.

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6. Deburring and Edge Trimming

After casting or stamping, the medal is not yet ready for plating.

The raw medal may have:

• Sprues
• Runner marks
• Sharp edges
• Flash
• Casting lines
• Excess material

These need to be removed.

The process can include:

Cutting → Deburring → Edge Trimming → Surface Preparation

This stage is extremely important because defects remaining on the metal surface can become much more visible after plating.

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7. Polishing

After trimming, the medal is polished.

The objective is to:

• Smooth the surface
• Remove minor imperfections
• Improve edge quality
• Prepare the medal for plating
• Create the desired surface appearance

A current manufacturing description notes that polishing may be performed mechanically and manually, with edges and faces treated carefully to avoid destroying sharp design details.

Important Manufacturing Principle

Plating does not hide poor polishing.

In fact, a shiny finish can make surface defects easier to see.

This is why the quality of the medal before plating is critical.

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8. Surface Treatment and Electroplating

Now the medal receives its metallic finish.

Common finishes include:

• Gold
• Silver
• Bronze
• Copper
• Black nickel
• Rose gold
• Antique gold
• Antique silver
• Antique copper
• Matte finishes
• Dual plating

A typical surface-treatment sequence can involve:

Degreasing → Cleaning → Base Plating → Color Plating → Rinsing → Drying → Protective Treatment

One detailed manufacturer process describes degreasing and ultrasonic cleaning followed by copper base layers, final color plating and drying; its stated example uses a 100°C drying stage for 40 minutes. These are specific process parameters from that manufacturer and should not be treated as universal factory settings.

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9. Why Plating Changes the Appearance So Much

Consider the same medal with three different finishes:

Polished Gold

Creates a bright, premium appearance.

Antique Gold

Darkens recessed areas and highlights raised details.

Antique Silver

Can create a traditional or historical appearance.

Therefore, plating is not simply a protective process.

It is part of the visual design.

For detailed military, firefighter and commemorative medals, antique finishes can provide stronger contrast between raised and recessed areas.

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10. Enamel Color Filling

If the medal contains color, the next stage may be enamel filling.

Two common options are:

Soft Enamel

Color is placed into recessed metal areas.

The metal borders remain raised.

This creates a textured appearance.

Hard Enamel

The enamel surface is polished closer to the level of the metal, producing a smoother appearance.

Other Color Technologies

Depending on the design, manufacturers may also use:

• UV printing
• Digital printing
• Laser engraving
• Translucent enamel
• Glitter
• Glow effects

A current manufacturing specification lists soft enamel minimum fill widths around 0.3 mm and imitation hard enamel around 0.5 mm, illustrating how very small color areas need to be considered during engineering. Again, these are manufacturer-specific production capabilities rather than universal industry limits.

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11. Printing and Laser Engraving

Not every design can be reproduced efficiently with enamel.

Printing may be more appropriate for:

• Fine text
• Photographic details
• Gradients
• Complex images
• Variable information

Laser engraving can be useful for:

• Names
• Serial numbers
• Dates
• Personalized awards

For example, a corporate service medal could use the same basic medal design while engraving each employee’s name individually.

This creates a standardized product with personalized information.

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12. Ribbon Manufacturing

A medal is normally paired with a ribbon.

Ribbon options include:

• Satin
• Woven
• Sublimated
• Printed
• Custom neck ribbon

Applications may include:

Marathon

Event logo + race colors

Military

Unit colors + insignia

Corporate

Brand colors + company logo

School

School colors + competition name

A current manufacturing specification describes standard adult medal ribbons in the approximate range of 860–900 mm × 20–30 mm, while children’s ribbons may be shorter. These dimensions vary by market and customer specification.

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13. Ribbon Attachment and Assembly

The ribbon is then attached to the medal.

Possible hardware includes:

• Jump ring
• D-ring
• Connector
• Pin
• Custom attachment

The medal may also be assembled with:

• Spinning components
• Moving parts
• Additional charms
• Decorative elements
• Custom accessories

This is where a multi-component medal becomes a finished award rather than simply a metal disc.

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14. Quality Control

Quality control should not happen only after the medal is finished.

A professional production system should check the product at multiple stages.

Incoming Material Inspection

Check:

• Metal material
• Alloy consistency
• Plating chemicals
• Enamel materials
• Ribbon materials

Casting Inspection

Check:

• Cracks
• Air holes
• Incomplete filling
• Deformation
• Surface defects

Plating Inspection

Check:

• Color
• Coverage
• Bubbles
• Flow marks
• Surface consistency

Enamel Inspection

Check:

• Color accuracy
• Pinholes
• Contamination
• Fill completeness
• Surface quality

One detailed current manufacturing process describes QC at incoming-material, post-casting, post-plating and post-enamel stages.

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15. Final Inspection and Packaging

Before shipment, finished medals should be checked for:

• Quantity
• Dimensions
• Finish
• Color
• Ribbon
• Assembly
• Surface defects
• Packaging

Then they can be packed individually or according to the customer’s requirements.

Common packaging includes:

• Polybags
• Cardboard boxes
• Plastic boxes
• Velvet pouches
• Premium presentation boxes

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Custom Medal Production Time: Where Does the Time Go?

A typical production schedule may look like:

Manufacturing Stage	Typical Time*
Artwork / engineering	1–3 days
Mold making	5–7+ days
Casting / stamping	1–3 days
Deburring & polishing	1–3 days
Plating	1–2 days
Enamel / printing	1–3 days
Ribbon / assembly	1–2 days
QC & packaging	1–2 days
Typical total	~12–20+ production days

*These are planning ranges rather than guaranteed lead times. Published manufacturer schedules currently cite approximately 5–7 days for standard mold making and around 12–18 days for mass production in some projects.

Rush projects can be faster, but they may involve additional production charges and increased scheduling pressure.

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Data Analysis: Which Manufacturing Steps Have the Biggest Impact?

Not every process contributes equally to cost and quality.

A useful way to analyze custom medal production is:

Factor	Cost Impact	Quality Impact	Design Impact
Artwork	Medium	High	Very High
Mold	High	Very High	Very High
Material	High	High	Medium
Casting/Stamping	High	Very High	High
Polishing	Medium	Very High	Medium
Plating	Medium–High	Very High	High
Enamel	Medium	High	High
Ribbon	Low–Medium	Medium	High
Packaging	Low–High	Medium	Medium
QC	Low direct cost	Very High	Low

Key conclusion

Mold + metal forming + surface finishing are usually the three most important technical stages.

A beautiful artwork cannot compensate for a poor mold.

A good mold cannot compensate for poor polishing.

Good polishing cannot compensate for inconsistent plating.

That is why medal manufacturing should be treated as a connected production system.

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Data Analysis: Why Quantity Reduces Unit Cost

Consider a simplified example.

Suppose the project has:

$100 tooling cost

100 medals

$100 ÷ 100 = $1.00 tooling cost per medal

500 medals

$100 ÷ 500 = $0.20 per medal

1,000 medals

$100 ÷ 1,000 = $0.10 per medal

The tooling itself did not become cheaper.

The cost was simply distributed across more units.

Current published pricing demonstrates this economy of scale. For example, one 2026 supplier lists a standard 2.5-inch zinc-alloy medal at approximately $3.50–$5.00 for 100 pieces, $2.20–$3.50 for 500 pieces, while another supplier’s published pricing falls from $4.63 at 100 pieces to $2.89 at 1,000 pieces for a specific 3-inch medal.

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Data Analysis: Size Has a Major Effect on Cost

Size affects:

• Material consumption
• Mold area
• Polishing area
• Plating area
• Shipping weight
• Packaging

One current U.S. supplier’s published approximate pricing illustrates the relationship:

Size	100–299 pcs	500–999 pcs	1,000+ pcs
2″	$6.50	$3.46	$3.26
3″	$9.64	$6.26	$5.98
4″	$14.46	$11.24	$10.62

These are supplier-specific prices, but the pattern is useful: larger medals generally carry higher unit costs, even at the same quantity.

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Study Case 1: 500 Marathon Medals

Customer Requirement

A marathon organizer requires:

• 500 medals
• 65 mm diameter
• Zinc alloy
• 3D center design
• Antique gold
• Two enamel colors
• Custom ribbon

Manufacturing Analysis

The manufacturer recommends:

3D die casting + antique plating + soft enamel + custom ribbon

Why?

Because the customer wants a visually strong medal but also needs to control the budget.

A current published 2026 factory pricing reference places many standard 500-piece zinc-alloy medals around $2.20–$3.50 per piece, while more complex 3D medals are listed around $3.80–$5.80.

Lesson

The buyer should not automatically choose the cheapest manufacturing process.

The better question is:

Which process creates the required appearance at the lowest reasonable total cost?

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Study Case 2: Corporate Recognition Medal

Requirement

1,000 medals

• 60 mm
• Corporate logo
• 10-year recognition
• Two colors
• Polished silver
• Custom ribbon

The artwork initially contains very small text.

Engineering Recommendation

The manufacturer enlarges the smallest lettering and simplifies the background.

Why?

Because a small design that looks acceptable on a computer may not remain readable after metal production.

Result

The final medal contains fewer unnecessary details but has:

• Better readability
• Cleaner relief
• Better plating contrast
• More consistent production

Manufacturing Lesson

Simplifying artwork can improve both appearance and manufacturing reliability.

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Study Case 3: Premium Championship Medal

Requirement

500 medals:

• 75 mm
• 3D relief
• Custom cut-outs
• Dual plating
• Three enamel colors
• Woven ribbon
• Presentation box

This is significantly more complicated than a basic die-struck medal.

The production route may include:

3D engineering → complex mold → die casting → polishing → dual plating → enamel → ribbon → premium packaging

The cost will naturally be higher because the medal has more manufacturing operations.

Lesson

A higher price should be evaluated against the additional manufacturing value, rather than simply compared with the price of a basic medal.

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Application Areas for Custom Medals

The manufacturing process is used across many industries.

Marathon & Running

• 5K
• 10K
• Half marathon
• Full marathon
• Trail running

Sports

• Soccer
• Basketball
• Swimming
• Wrestling
• Golf
• Cycling
• Martial arts

Schools

• Academic awards
• Student competitions
• Graduation
• Science fairs

Corporate

• Employee recognition
• Years of service
• Corporate anniversaries
• Sales awards

Military

• Service recognition
• Unit awards
• Retirement
• Commemorative events

Police & Firefighter

• Years of service
• Retirement
• Special recognition
• Department anniversaries

Government & Organizations

• Public service
• Organizational anniversaries
• Recognition programs

Memorial & Commemorative

• Historical events
• Memorial ceremonies
• Anniversaries
• Special commemorations

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How to Reduce Custom Medal Manufacturing Costs

If the budget is limited, consider these strategies.

1. Increase the Quantity

Higher volume generally reduces the per-unit share of tooling and setup costs.

2. Use Standard Sizes

Avoid unnecessarily oversized medals.

3. Simplify 3D Relief

Not every area needs deep 3D relief.

4. Reduce Unnecessary Colors

Use colors where they actually improve the design.

5. Select Standard Plating

Gold, silver, bronze and antique finishes are often easier to produce than highly specialized finishes.

6. Plan Production Early

Avoiding rush production gives the factory more scheduling flexibility.

7. Compare Complete Quotations

Always compare:

Medal + Mold + Ribbon + Packaging + Shipping

rather than just the medal unit price.

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How to Choose a Custom Medal Manufacturer

Ask these questions before placing an order:

Manufacturing

• Can you make 2D and 3D medals?
• Do you use zinc alloy, brass, copper or iron?
• Can you make custom shapes?
• Can you produce cut-outs?
• Can you manufacture double-sided designs?

Finishing

• What plating options are available?
• Can you provide antique finishes?
• Can you make dual plating?
• Do you offer soft and hard enamel?
• Can you do UV printing or laser engraving?

Quality

• How is the mold inspected?
• How is plating checked?
• How is enamel color controlled?
• Is there final QC?
• Can you provide production photos?

Commercial

• What is the MOQ?
• Is mold cost included?
• What is the production lead time?
• Is the ribbon included?
• Is packaging included?
• What shipping options are available?

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Why Choose ChallengeCoinBadges?

ChallengeCoinBadges is a professional OEM and ODM custom metal product manufacturer with 20+ years of manufacturing experience and a team of 100+ employees.

Our product range includes:

• Custom Medals
• 3D Medals
• Sports Medals
• Marathon Medals
• Military Medals
• Challenge Coins
• Military Coins
• Police Badges
• Lapel Pins
• Cufflinks
• Metal Emblems

Our manufacturing capabilities cover the complete process from artwork review and mold engineering to metal forming, polishing, plating, enamel, assembly and quality inspection.

We understand that different applications require different manufacturing solutions.

A marathon medal may prioritize quantity, visual impact and cost efficiency.

A military medal may prioritize insignia accuracy and detailed relief.

A corporate medal may emphasize brand consistency and premium finishing.

A championship medal may prioritize large dimensions, 3D relief and special effects.

The manufacturing process should therefore start with the purpose of the medal, not simply the physical product.

Request a Custom Medal Quote

Send:

Artwork + Quantity + Size + Thickness + Material + Finish + Enamel + Ribbon + Application

Our team can evaluate the design and recommend an appropriate production method.

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

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FAQ: How Are Custom Medals Made?

What material is commonly used for custom medals?

Zinc alloy is widely used for custom medals because it supports complex shapes, 3D relief and cut-outs. Brass, copper and iron can also be used depending on the manufacturing method and desired appearance.

How long does it take to make custom medals?

A common planning range is approximately 12–20+ production days, although actual lead time depends on mold complexity, quantity, finishing and factory scheduling. Some current manufacturers cite approximately 5–7 days for standard mold production and 12–18 days for mass production.

Are 3D medals more expensive?

Usually. More complex 3D geometry requires additional mold engineering and production work. Published 2026 pricing examples show higher prices for 3D medals than standard zinc-alloy medals at comparable quantities.

What is the difference between casting and stamping?

Die casting injects molten metal into a mold and is especially useful for complex 3D zinc-alloy designs.

Stamping/die striking forms sheet metal under high pressure and is commonly used for brass, copper or iron designs.

Can custom medals have different colors?

Yes. Depending on the design, manufacturers can use soft enamel, hard enamel, printing or other decorative techniques.

Can names be added to each medal?

Yes. Laser engraving or other variable-data processes can be used for names, dates, numbers and personalized information.

Does every medal need a custom mold?

For custom die-cast or die-struck medals, a production die/mold is generally required. However, the tooling method depends on the manufacturing process.

What makes a custom medal expensive?

The major cost drivers include:

Quantity + Size + Thickness + Material + Mold Complexity + 3D Relief + Plating + Enamel + Ribbon + Packaging

How can I get an accurate quote?

Send the manufacturer your artwork, quantity, size, thickness, preferred material, finish, enamel colors, ribbon requirements and delivery destination.

The more complete the specification, the more meaningful the quotation will be.

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Final Conclusion

Custom medals are manufactured through a sequence of carefully controlled processes:

Design → Engineering → Mold → Casting/Stamping → Deburring → Polishing → Plating → Coloring → Ribbon Assembly → QC → Packaging

The most important lesson is that medal quality is cumulative.

A strong design needs a good mold.

A good mold needs accurate metal forming.

Accurate metal forming needs proper polishing.

Good polishing provides the foundation for quality plating.

And all of these stages ultimately determine what the customer receives.

For buyers, event organizers and distributors, understanding this process makes it easier to evaluate suppliers, compare quotations and avoid unnecessary manufacturing costs.

ChallengeCoinBadges provides OEM/ODM custom medal manufacturing for sports events, marathons, schools, corporations, military organizations, police departments, firefighters and commemorative programs.

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