Soft Enamel vs. Hard Enamel: Key Differences for Metal Badges and Medals
Metal badges and medals have become central to celebration, reward, and branding. Their tactile colors and lasting shapes make them desirable for sports events, corporate identity, service recognition, and collectibles. But one decision shapes how these awards look and feel: the choice between soft and hard enamel. In this comprehensive guide, you’ll learn the differences in the enamel medal process, see how each type is manufactured, discover their typical uses, and compare costs. We’ll feature close-up examples—including sports medals, lapel pins, and brand badges—to help you make the right decision for your project.
The Enamel Medal Process: Core Steps Explained
Enamel badge and medal manufacturing begins with careful material selection and precise forming. Top choices include zinc alloy, brass, iron, and stainless steel. Each has its own profile for strength, detail, and finishing options. After picking a base, the process includes:
- Mold Making: Designers sculpt a 2D or 3D master using CAD software. For fine detail, wire EDM machines carve steel molds with tight tolerances (as narrow as ±0.05 mm).
- Die Casting or Stamping: Sheets or molten metal take shape under heavy pressure. All badges and medals are then trimmed, deburred, and tumbled for smooth edges.
- Plating: The pieces receive electroplated finishes like gold, nickel, antique brass, or black zinc. Thickness is checked (typically 3–8 μm) to ensure both beauty and durability.
- Enamel Filling: Now comes the crucial step—you can choose soft or hard enamel. This choice governs how color behaves within the recessed or leveled metal wells.
- Baking and Polishing: Parts are baked to cure enamel, then polished or sanded (as needed) for the desired finish.
- Assembly and Packing: Depending on application, products might get split rings, butterfly clutches, magnetic backs, or custom card packaging.
Each step affects cost, timeline, and end-user experience. Gairun, a trusted OEM/ODM manufacturer, brings precision and care to every stage, meeting international quality standards while offering quick turnaround for B2B projects.
Soft Enamel vs. Hard Enamel: Key Differences for Metal Badges and Medals
Soft enamel and hard enamel may look similar at first, but the difference runs deeper. Their unique visual effects, tactile qualities, and best-use cases set them apart. Let’s break down what sets each apart.
What Is Soft Enamel?
Soft enamel uses colored enamel paint—usually matched to Pantone shades—poured into recessed areas of a die-cast or stamped badge. The enamel sits below the metal lines, creating a textured, ridged surface. Key features include:
- Recessed Feel: You can feel the metal lines outlining each color. This relief gives visual depth, making designs pop under light.
- Vivid Colors: Soft enamel colors often appear brighter, adding personality to promotional or event medals.
- Protective Epoxy Option: A clear dome can be added for extra durability and a glossy finish.
- Production Efficiency: Soft enamel badges and medals often require less labor for small runs, leading to shorter lead times and lower costs.
What Is Hard Enamel?
Hard enamel—sometimes called “cloisonné”—involves heating the enamel powder at high temperatures (up to 800°C) until it hardens completely. The badge is then polished so that both the metal and enamel sit evenly, producing a flat and ultra-smooth finish. Characteristics include:
- Flat, Glossy Surface: The enamel and metal are flush, feeling glass-smooth to the touch.
- Exceptional Durability: Hard enamel resists scratches, fading, and wear, even with frequent handling.
- Rich, Jewel-like Colors: The cured enamel has a deep, luminous quality ideal for high-status awards and fine branding.
- Time-Intensive: Multiple polishing and firing steps add to production time and cost but yield unmatched longevity.
| Aspect | Soft Enamel | Hard Enamel |
|---|---|---|
| Surface | Recessed, tactile (metal above color) | Flat, smooth (color and metal flush) |
| Appearance | Bright, bold colors with visible outlines | Polished, glassy finish with deep hues |
| Durability | Good (may chip if scratched hard) | Excellent (very scratch-resistant) |
| Process Time | Faster (single bake, optional epoxy) | Slower (multiple layers, high-temp firing, hand-polish) |
| Cost | Lower (typically 15–40% less) | Higher (reflects extra labor and expertise) |
| Best For | Lapel pins, fun badges, promo medals | Honor medals, fine collectibles, luxury branding |
Visual Effects and Surface Differences
The major difference between soft and hard enamel is tactile. With soft enamel, your fingers feel the dips and rises of the design. Light creates shadows along ridges, adding energy to logos and graphics. The colors sparkle against the metal background, which can be plated in antique, satin, or bright finishes. Some clients add an epoxy dome for a glossy shield—great for school badges or promotional coins.
By contrast, hard enamel’s beauty lies in precision. The surface is completely flat and mirror-like after multiple rounds of hand polishing. Light glides off it. This finish feels valuable—almost like glass—making it sought after for business and club badges, branded nameplates, and round medals honoring years of service.
Expert Takeaway: Soft enamel delivers vibrant contrast and tactile delight at value, while hard enamel achieves museum-grade smoothness ideal for elite awards.
Materials, Production Steps, and Durability
Different base metals respond uniquely to the enamel processes. Zinc alloy is versatile and affordable, ideal for soft enamel medals or large custom shapes. Brass excels in fine detail and hard enamel’s repeated baking. Stainless steel (304) can be laser engraved for crisp edges, while iron remains a favorite for stamped badges and magnetic tags. Hard enamel works best with smooth, non-porous bases (brass, copper).
Step-by-Step: Soft Enamel Badge Manufacturing
- Start with a molded or stamped blank—shaped and trimmed for crisp lines.
- Apply chosen electroplating: nickel, antique gold, matte black, chrome, or rose gold.
- Pipette liquid soft enamel into the recessed areas, one color at a time. Each well is filled with care, often under magnification.
- Send badges through an oven (baked at 80–120°C) for 10–20 minutes to set color.
- Add a clear epoxy dome (optional) for improved scratch and impact resistance.
Step-by-Step: Hard Enamel Medal Production
- Begin with a die-struck or cast blank in brass or copper for optimum polishability.
- Hand-fill powdered, glass-like enamel into each cell, slightly overflowing the design.
- Fire at high heat (≥800°C) so the powder hardens and adheres to the metal base.
- Repeat enamel and baking for each color layer. Some badges require 4–8 firings.
- Polish with fine abrasives to level the enamel and metal, achieving a seamless finish.
- Inspect surface luster and uniform color, checking against AQL and relevant ASTM B117 salt spray standards for corrosion resistance.
Hard enamel’s labor involves hundreds of precise touches, explaining both higher cost and exceptional quality.
Applications: When to Choose Soft vs. Hard Enamel
Which enamel suits your project depends on the target audience, use case, and budget. Let’s break it down by popular applications.
Sports Medals
- Soft Enamel: Marathon, cycling, and e-sport medals use soft enamel for bold colors and variety on a budget. They stand up well to event-day handling and look lively in group photos.
- Hard Enamel: Given to winners or VIPs—these medals feel prestigious, with deep color and a flawless surface that stand the test of time and repeated handling.
Lapel Pins and Brand Badges
- Soft Enamel: Common for awareness ribbons, corporate giveaways, and club membership pins. Textured metal catches light and enhances playful or vibrant designs.
- Hard Enamel: Chosen for high-end branding (luxury hotels, auto clubs) or retail collectibles. The finish resists scratches, perfect for frequent wear.
Nameplates and Corporate Labels
- Soft Enamel: Adds affordable color to machinery or luggage tags. Best where design complexity or high quantities are important.
- Hard Enamel: Suits executive awards and premium appliances where every detail must remain crisp for years.
Commemorative Coins & Souvenirs
- Soft Enamel: Works for high-volume giveaway coins and tourist souvenirs where variety trumps absolute polish.
- Hard Enamel: Used for limited edition or military challenge coins that must endure passing between collectors.
Price Differences: Breaking Down the Costs
Soft enamel badges and medals are usually 15–40% less expensive than hard enamel items of the same size and design. Costs reflect material, mold complexity, relief depth, and the number of enamel color fills. Labor is the greatest factor—hard enamel requires many more hand-filling, baking, and polishing steps. Some real-world price ranges observed in bulk B2B orders:
- Soft Enamel Medals (50 mm, zinc alloy, antique finish): $0.80–$1.60 per piece (MOQ: 100–300 pcs)
- Hard Enamel Medals (50 mm, brass, gold plate): $1.30–$2.80 per piece (MOQ: 100–300 pcs)
- Soft Enamel Lapel Pins (25 mm): $0.35–$0.90 per piece
- Hard Enamel Pins (25 mm): $0.70–$1.30 per piece
For custom shapes or intricate design, expect setup fees for mold-making (from $60–$150). Hard enamel projects may require higher MOQs (minimum order quantities) to offset manual labor. Lead times also differ: soft enamel pins or medals can be ready in 12–18 days, while hard enamel takes 16–25 days or more for complex designs.
Close-Up Examples: Comparing Finish and Craftsmanship
Case Study: Soft Enamel Sports Medal
A cycling event ordered 3,000 soft enamel medals, using a zinc alloy base, antique silver plating, and five Pantone-matched colors. The resulting medals showed bright team colors and sharp relief, with metal lines separating icons and text. Soft enamel delivered a memorable, photo-ready finish that stayed affordable within the club’s budget and 3-week lead time.
Case Study: Hard Enamel Brand Badge
A luxury automobile network wanted 500 hard enamel badges bearing their shield and gold logo. By starting with a pure brass base, Gairun produced flush, gleaming badges. Hand-polished surfaces reflected showroom lights, wowing VIP clients. After 10 days of prototype reviews, production wrapped up in 4 weeks—including AQL inspection and REACH compliance paperwork for peace of mind.
Case Study: Lapel Pin Set
An environmental foundation requested two pin types: one for fundraisers, another for board members. Soft enamel delivered playful, bright tree pins for donors, while hard enamel created slick, smooth recognition pins for VIPs. Both included butterfly clasps and OPP bag packaging.
Choosing the Right Enamel: Buyer Guidance
Picking between soft and hard enamel depends on more than just visual taste. Here are key factors to weigh:
- Intended Use: Everyday items (promo pins, fans’ medals) suit soft enamel’s price and playful look. Top-tier awards or keepsakes benefit from hard enamel’s feel and durability.
- Budget and Quantity: For tight timelines or large quantities, soft enamel offers value. High-end branding or executive gifts justify hard enamel’s higher investment.
- Design Detail: Smaller text and tight, complex graphics look cleaner with hard enamel polishing. Bold or playful designs shine in soft enamel.
- Finishing Options: Epoxy domes, custom metal textures, and packaging can enhance the chosen enamel further. Discuss these with your manufacturer.
Partnering with a seasoned OEM/ODM like Gairun ensures best-fit solutions, from raw material selection to international compliance and quality control (AQL, XRF, ASTM D3359, etc.).
Latest Trends: Customization, Finishes, and Compliance
Industry clients now demand more than color—they want tactile finishes, custom shapes, and reliable compliance. Current trends include:
- Dual-Finish Medals: Combining soft and hard enamel on a single piece for layered effects.
- Antique & Brushed Metal: Popular for corporate and military coins, offering a timeless look with enamel contrast.
- Advanced Plating: Matte black, PVD rose gold, and mixed plating attract younger, design-forward audiences.
- Eco-Friendly Choices: Using RoHS/REACH-compliant metals and non-toxic enamel colors to meet global standards for wearables.
- Premium Packaging: Custom velvet boxes, blister packs, or cardboard cards elevate the unboxing experience.
Quality-conscious buyers should confirm that suppliers use lead- and nickel-safe processes, especially on products worn on the skin (EN 1811).
Opportunities and Next Steps with Gairun
As a leading manufacturer of medals, badges, coins, and branded hardware, Gairun brings craftsmanship and technical skill to every OEM/ODM order. Their experienced teams advise on the best enamel type, material, and finish for your industry and budget. Gairun’s production lines handle high-mix, custom B2B runs with strict AQL checks, RoHS/REACH compliance, and global logistics. Whether you’re planning a marathon, launching a membership campaign, or elevating your brand, expert guidance ensures memorable, long-lasting results.
To explore options or get samples, contact Gairun’s commercial team with your artwork, material preferences, or compliance needs. They welcome business and design inquiries for both short runs and large B2B campaigns.
Frequently Asked Questions
What makes soft enamel different from hard enamel in badges and medals?
Soft enamel sits below the stamped metal lines, creating a textured surface with vivid colors, while hard enamel is polished flat for a smooth, glass-like finish. The process and feel of each are unique, with hard enamel being more durable and premium.
Which enamel type is better for sports medals or event awards?
Soft enamel suits most sports medals due to its affordability, bold look, and quick production. Hard enamel is favored for top-tier awards because its flat surface, richer color, and scratch resistance give a sense of prestige and longevity.
Why is there a price difference between soft and hard enamel?
Hard enamel costs more due to extra labor, repeated firing, and hand polishing. Soft enamel requires fewer steps and less manual work, making it more budget-friendly for large orders or frequent giveaways.
How do I choose the right finish for my enamel badges or medals?
Consider your intended audience, required durability, design details, and budget. For playful pins or mass promotions, soft enamel fits well. For luxury branding, long-term recognition, or executive gifts, pick hard enamel for its premium look and resilience.
Can soft or hard enamel badges be made with custom plating or packaging?
Yes, both types allow for choices in plating (gold, nickel, matte black, etc.) and packaging (OPP bags, velvet boxes, custom cards) to boost branding and presentation. Discuss finishing and packaging options with your manufacturer to fit your goals.
What quality and compliance checks should I request from my manufacturer?
Ask about AQL inspection, plating thickness, color accuracy, salt spray tests, and international standards such as RoHS, REACH, and EN 1811 for metal items worn against the skin. Quality manufacturers like Gairun provide full compliance and testing support.
