The metal medal customization process is a systematic workflow that combines design, material selection, precision manufacturing, and surface finishing to create unique, high-quality medals for events (e.g., sports competitions, academic awards, corporate ceremonies) or commemorative purposes. Below is a detailed, step-by-step breakdown of the entire process:
1. Demand Communication & Requirement Confirmation
This is the foundational stage to ensure the final medal aligns with the customer’s vision. Both parties clarify core details to avoid deviations later:
Purpose & Theme: Confirm the medal’s use (e.g., Olympic-style sports medal, employee recognition, anniversary commemoration) and core theme (e.g., "2024 City Marathon," "Innovation Award").
Key Specifications:
Size & Thickness: Common sizes range from 30mm (small commemorative medals) to 80mm (large competition medals); thickness is usually 2mm–5mm (adjustable for weight and durability).
Shape: Standard options (circular, square, oval) or custom shapes (e.g., star, shield, sport-specific outlines like a runner or trophy).
Design Elements: Logos, text (event name, recipient category, date), patterns (engravings, reliefs), and color accents (enamel, printing).
Quantity: Small batches (50–200 pieces, for local events) or large batches (1,000+ pieces, for national competitions) affect manufacturing method choices.
Budget: Determines material selection (e.g., brass vs. zinc alloy) and finishing processes (e.g., gold plating vs. spray painting).
2. Material Selection
The choice of metal directly impacts the medal’s appearance, weight, durability, and cost. Common materials include:
Material
Characteristics
Suitable Scenarios
Brass
High ductility (easy for complex engravings), warm golden base color, corrosion-resistant.
Mid-to-high-end medals (e.g., championship awards).
Zinc Alloy
Low cost, good casting performance (ideal for 3D reliefs), lightweight but less durable than brass.
Budget-friendly, large-batch medals.
Copper
Rich reddish-brown tone, high malleability, develops a unique patina over time.
Vintage-style or commemorative medals.
Iron/Steel
High strength, heavy weight (for a "premium feel"), but prone to rust (requires plating).
Large, heavy-duty medals (e.g., military honors).
Stainless Steel
Corrosion-resistant, scratch-proof, sleek silver appearance.
Outdoor-use medals or long-term keepsakes.
Note: For "premium" looks (e.g., gold/silver medals), base metals are often paired with plating (e.g., brass plated with 24K gold).
3. Design & Proofing
This stage transforms ideas into visual and physical prototypes, ensuring the design is feasible and meets expectations:
2D Design Drafting:
Designers use software (e.g., Adobe Illustrator, CAD) to create detailed 2D renderings, including:
Front/back layouts (logo placement, text font/size, pattern details).
Color specifications (Pantone codes for enamel or printing).
Technical marks (e.g., where to add a ribbon loop, edge finishes like "serrated" or "smooth").
3D Modeling (for Relief/3D Effects):
If the medal includes 3D elements (e.g., raised logos, sculpted figures), 3D modeling software (e.g., SolidWorks) is used to create a digital 3D model, showing depth and texture.
Prototype Production:
A physical sample (prototype) is made using low-cost methods to test feasibility:
For simple designs: CNC engraving on a small metal plate to verify 2D details.
For 3D designs: 3D printing (resin or metal) to simulate relief effects, or soft die casting (for zinc alloy prototypes).
Confirmation & Revision:
The customer reviews the prototype for design accuracy, size, and feel. Revisions (e.g., adjusting text size, modifying a pattern) are made until full approval is given.
4. Mold Making (for Mass Production)
Once the prototype is approved, a production mold is created—this is critical for ensuring consistency across all medals:
Mold Material:
For small batches (≤500 pieces): Aluminum molds (low cost, fast production).
For large batches (≥1,000 pieces): Steel molds (high durability, can withstand repeated use).
Mold Processing:
Using CNC machining or electrical discharge machining (EDM), the approved design (2D/3D) is carved into the mold. For 3D reliefs, the mold is precision-cut to replicate the exact depth and shape of the prototype.
Mold Testing:
A small number of "test medals" are produced using the new mold to check for defects (e.g., incomplete filling, uneven edges). The mold is polished or adjusted if issues arise.
5. Metal Forming & Shaping
This stage produces the "raw" medal blanks (unfinished metal pieces) using the mold:
Common Forming Methods:
