The Complete Custom Medal Production Process Explained

The Complete Custom Medal Production Process Explained

Custom medals are more than just awards—they represent achievement, memories, and brand identity. Whether for marathons, school competitions, sports tournaments, military recognition, or corporate events, understanding the custom medal production process helps buyers make smarter decisions and avoid costly mistakes.

In this guide, we explain how custom medals are made step by step, from concept artwork to final delivery. If you’re planning to order custom medals in bulk, this article will help you understand timelines, materials, mold fees, and quality control.

1. Step One: Medal Design and Artwork Creation

Every custom medal begins with an idea.

Before manufacturing starts, the customer provides:

• Logo or event branding
• Medal shape and size
• Text and wording
• Ribbon design requirements
• Preferred finishing (gold, silver, bronze, antique, matte, shiny, etc.)

Professional manufacturers convert your concept into a 2D or 3D digital artwork proof.

What Happens During the Design Stage?

Designers typically prepare:

• Front medal design
• Back medal design
• Engraving details
• Cut-out areas
• Layered 3D effects
• Color filling specifications
• Ribbon attachment style

A digital proof is then sent for approval before production begins.

Important Tip

Always check:

• Spelling
• Event dates
• Logo placement
• Medal dimensions
• Colors
• Finish selection

Once approved, changes later may increase costs.

2. Mold Making (Tooling Production)

After artwork approval, the next stage is creating the medal mold.

The mold acts like a metal stamp that forms the medal’s shape and details.

Manufacturers usually create molds using:

• CNC engraving
• Precision carving
• Die-struck mold techniques

The mold captures every detail including:

• Logos
• Textures
• Raised surfaces
• Recessed areas
• 3D sculpting effects

Why Mold Fees Exist

Most custom medal manufacturers charge a one-time mold fee because every medal design requires a unique tool.

The good news is:

Many factories keep molds for future reorders, reducing costs for repeat customers.

3. Material Selection for Custom Medals

Choosing the right material affects cost, durability, and appearance.

Common medal materials include:

Zinc Alloy

The most popular option for custom medals.

Advantages:

• Great for complex 3D designs
• Excellent for cut-out shapes
• Strong durability
• Cost-effective for bulk production

Best for:

• Running medals
• Sports medals
• Corporate awards

Iron

A lower-cost option.

Advantages:

• Budget friendly
• Durable
• Suitable for simple stamping

Best for:

• School competitions
• Low-budget events

Brass or Copper

Premium options with elegant finishing.

Advantages:

• Better texture
• Premium feel
• Superior plating quality

Best for:

• Luxury commemorative medals
• Executive awards

4. Die Casting or Stamping Process

This is where the physical medal begins taking shape.

Depending on material and design, manufacturers use either:

Die Casting

Typically used for:

• Zinc alloy medals
• Complex 3D medals
• Hollow designs
• Cut-out medals

Molten metal is injected into the mold under pressure.

Die Striking / Stamping

Typically used for:

• Iron medals
• Flat medal designs
• Traditional award medals

A hydraulic press stamps metal into shape.

After shaping, excess edges are trimmed and polished.

5. Polishing & Surface Preparation

Raw medals often look rough after molding.

Workers polish medals to create smooth edges and improve detail clarity.

This stage improves:

• Surface smoothness
• Edge finishing
• Shine quality
• Texture visibility

For premium medals, multiple polishing rounds may be performed.

6. Electroplating Process

Electroplating gives medals their final metallic appearance.

Popular plating options include:

Shiny Gold

Bright and reflective.

Best for:

• Premium sports medals
• Luxury events

Matte Gold

Elegant and modern appearance.

Best for:

• Corporate awards
• Premium marathon medals

Silver Finish

Classic and professional.

Best for:

• Achievement awards
• School recognition

Antique Finishes

Includes:

• Antique gold
• Antique silver
• Antique bronze
• Antique copper

Best for:

• Vintage-themed events
• Military medals
• Heritage competitions

The plating process also protects medals from corrosion.

7. Color Filling (Soft Enamel Process)

Many custom medals include color.

Manufacturers usually use:

Soft Enamel

The most common option.

Benefits:

• Vibrant colors
• Durable finish
• Affordable pricing

UV Printing

Ideal for:

• Gradient colors
• Detailed artwork
• Photo-quality graphics

Epoxy Coating

Optional protective layer.

Benefits:

• Scratch resistance
• Glossy appearance
• Better durability

8. Ribbon Attachment and Customization

No medal is complete without a ribbon.

Custom ribbon options include:

• Sublimated printed ribbons
• Jacquard woven ribbons
• Satin ribbons
• Heat transfer printing

Popular ribbon customization:

• Event logo
• Date
• Sponsor branding
• Country themes
• Marathon names

A professionally designed ribbon can significantly improve medal appearance.

9. Quality Control Inspection

Before shipping, reliable medal factories conduct quality inspections.

Quality checks include:

Design Accuracy

Checking:

• Logo correctness
• Text spelling
• Color consistency

Finish Inspection

Checking:

• Scratches
• Plating defects
• Missing paint

Attachment Testing

Checking:

• Ribbon strength
• Jump ring durability

Quantity Verification

Ensuring correct production volume.

This stage reduces defect rates and protects event organizers from problems.

10. Packaging and Shipping

Once approved, medals are packed for shipping.

Common packaging options:

• Individual poly bags
• Velvet pouches
• Gift boxes
• Foam packaging
• Premium presentation boxes

For international orders, factories often use:

• DHL
• FedEx
• UPS
• Air freight
• Sea shipping for bulk orders

Typical Custom Medal Production Timeline

Here’s a general production timeline:

Total average production time:

10–25 days, depending on quantity and complexity.

Common Mistakes to Avoid When Ordering Custom Medals

1. Ordering Too Late

Production takes time, especially during marathon or sports seasons.

2. Ignoring Mold Approval

Incorrect artwork approval can lead to expensive remakes.

3. Choosing Cheap Materials Only

Low cost may reduce perceived quality.

4. Forgetting Ribbon Design

A premium ribbon improves overall presentation.

5. Not Requesting Samples

Always request production photos or samples for large orders.

Why Choose a Professional Custom Medal Factory?

An experienced manufacturer provides:

• Fast artwork support
• Professional mold creation
• Better plating consistency
• Strict quality control
• Global shipping experience
• Lower bulk pricing

For schools, marathon organizers, sports clubs, and businesses, working directly with a trusted medal factory ensures better quality and lower costs.

Final Thoughts

Understanding the complete custom medal production process helps you avoid delays, control costs, and create medals that leave a lasting impression.

From design → mold making → casting → plating → coloring → ribbon attachment → quality inspection, every step matters in producing premium custom medals.

If you’re planning an upcoming event, choosing an experienced manufacturer can make the process smoother and ensure your medals arrive on time and exactly as expected.