Introduction to Zinc Alloy Die Casting for Custom Medals
Zinc alloy die casting is one of the most reliable methods for producing custom medals. Its process guarantees precision, durability, and smooth, intricate details that make medals stand out in sports events, military commemorations, corporate awards, and branded gifts. In this guide, you’ll learn exactly how zinc alloy die casting works for custom medals, from the first mold design to the final polish.
Zinc Alloy Die Casting: What Sets It Apart?
In custom medal manufacturing, die casting means injecting molten metal—often zinc alloy—into high-strength steel molds. This method allows creators to craft medals with complex reliefs, sharp edges, and a flawless surface. Zinc alloys are popular due to their natural strength, corrosion resistance, and ability to capture fine detail. Die cast medals have a weighty, premium feel and are trusted to withstand everyday wear.
- Zinc Alloy: An engineered mix of zinc, aluminum, copper, and sometimes magnesium. Offers a hardness of ~90 HV and thicknesses down to 1.5 mm.
- Die Casting: High-pressure process for mass production—excellent for multi-layered, full-3D, or logo-intense medal designs.
- Applications: Sports medals, promotional coins, club badges, branded tags, and souvenir hardware.
Why Manufacturers Choose Die Casting for Medals
Zinc alloy die casting delivers clear advantages: consistent quality, detail-rich finishes, and cost efficiency at medium and large volumes. For buyers seeking sharp, custom 2D or 3D medals, it offers unmatched reliability compared to stamping or photo-etching.
Step by Step: How Zinc Alloy Die Casting Works for Custom Medals
Mold Making – The Foundation of Precision
Everything starts with the design. A medal design is translated into a steel mold using CAD software. CNC machining, wire EDM, and sometimes laser engraving create ultra-precise details. Relief heights, logo contours, and edge geometry are all programmed. Gairun uses high-grade tool steel (H13 or SKD11) to create molds that can withstand thousands of production cycles and keep every medal sharp, year after year.
Expert Tip:
“A well-made die not only defines the medal’s dimensions but prevents flash (excess metal) and ensures each edge is crisp.” – Medal Production Specialist at Gairun
Melting the Zinc Alloy
Once the mold is ready, zinc alloy ingots are loaded into a melting furnace. The alloy is heated to around 420°C—hot enough to become fully molten without oxidizing. Quality control is vital: The metal’s purity is checked, and melt temperature is tightly regulated to prevent shrinkage or porosity in finished medals.
Injection Into the Mold
The real action starts here. A shot of molten zinc alloy is injected into the closed steel mold at pressures of 8–14 MPa. The metal fills every nook—logo text, image reliefs, outer shapes. In just seconds, the liquid metal adopts the exact form of the mold, locking in every detail designed in the initial CAD stage.
Cooling and Solidification
As it cools (usually for 10–30 seconds), the zinc alloy hardens into its final shape. Water or air-cooling systems speed up the process. Quick solidification ensures the medal remains dense, with minimal micro-bubbles or weak spots. The mold halves open, and the new medal is ejected. Each piece gets checked visually for surface or dimensional flaws.
Trimming and Finishing
The next step is trimming: removing any excess metal (called flash) along the edges. Automated presses or skilled operators use precision tools to shape every outline. After trimming, medals may go through deburring, tumbling, or shot blasting—techniques that smooth rough spots and prepare them for surface finishing. At Gairun, strict tolerance controls ensure every piece matches specifications, often to within ±0.05 mm.
- Deburring removes sharp projections.
- Shot blasting creates a matte or textured finish.
- Tumbling polishes the medal for a bright, clean appearance.
Surface Finishing Options
Die cast medals can be finished in many ways. Electroplating adds metallic colors—antique brass, gold, nickel, gunmetal, or matte black. Colored enamel fills bring logos to life; epoxy domes protect soft enamel; sandblasting or brushing adds unique textures. Color separation and Pantone matching are used for brand consistency. Thickness of plating is measured by XRF technology and often ranges from 4–15 μm depending on the finish and use.
- Hard and soft enamel options: Protect and highlight details.
- Epoxy domes: Shield logos from scratches.
- Plating choices: Adjust for rust resistance, shine, or premium looks.
Assembly and Packaging
After finishing, medals are assembled with ribbons, split rings, or custom fasteners—chosen for the event type. Bulk medals might use OPP bags, while VIP awards could come in velvet boxes or custom blister packs. All items pass final sampling under AQL (Acceptable Quality Level) protocols, which guarantee consistency. Compliance with standards such as ASTM D3359 for adhesion, salt-spray testing, and RoHS/REACH certification is routine for Gairun’s export customers.
Die Cast vs. Stamped Medals: Which Is Right for Your Project?
Buyers often weigh die cast versus stamped medals based on design complexity, budget, and intended use. Die casting suits intricate, 3D reliefs and larger runs. Stamping (pressing sheet metal) is ideal for flatter, lighter, or low-budget medals. Here’s a comparison to help you decide:
| Feature | Die Cast Medals | Stamped Medals |
|---|---|---|
| Process | High-pressure injection, molten metal | Sheet metal pressed in dies |
| Thickness Range | 1.5–5 mm (3D possible) | 0.7–2 mm (mainly 2D) |
| Detail Level | High (2D/3D relief, sharp edges) | Moderate (basic designs, shallow relief) |
| Weight & Feel | Heavy, premium | Lighter, more flexible |
| MOQ | Typically 300+ | Can be 100+ |
| Lead Time | 3–5 weeks (incl. mold build) | 2–4 weeks |
| Cost | Higher upfront, lower unit as volume increases | Low upfront, consistent at smaller scale |
| Best Use | Sports, corporate, detailed custom work | Budget promos, simple giveaways, thin badges |
When to Choose Die Casting
- Need for deep 3D relief, custom shapes, or sharp text.
- Medium to large batch size — die cost spreads out.
- Desire for premium feel, durability, and finely plated finishes.
- Applications: Marathon medals, branded event awards, premium coins.
When Stamping Is Best
- Simple, flat designs — basic logo or outline.
- Lower MOQ, tight budgets.
- Lighter medals for kid’s events, quick-turn projects.
- Applications: Fun runs, school awards, bulk badges.
The Role of Zinc Alloy in Medal Manufacturing
Zinc alloy’s properties shine in medal making. Its balance of cost, durability, and malleability lets manufacturers create both budget-conscious and high-end awards. Unlike brass or stainless steel, zinc alloy supports intricate die work without cracking or deforming, making it ideal for custom die casting. Gairun’s facility guarantees process control, from alloy sourcing through plating and finishing, delivering medals that meet strict global standards like EN 1811 for nickel release and CPSIA limits.
Other Materials: A Quick Overview
- Brass: Rich gold tone, superior polish—higher cost, heavier.
- Stainless Steel (304/316): Maximum rust resistance, mirror polish—less mold detail.
- Aluminum (6061/5052): Lightweight, ideal for badges—limited casting detail.
- Iron/Steel: Economical, best for stamped or pressed designs—may rust without plating.
Designing Your Custom Die Cast Medal
From concept to completion, medal design is a creative and technical process. Medal size, thickness, relief depth, and color are set during the CAD stage. Gairun engineers guide B2B customers on what’s technically possible, such as 2D/3D combinations, hidden logo text, or multi-part assemblies (like coins with spinning centers). Confident design work minimizes production errors and ensures cost-efficient molds.
Medal Relief (2D vs. 3D)
- 2D: Flat layers, ideal for basic logos and text.
- 3D: Deep contours, lifelike images, multi-level text.
- Die casting supports both, with fill depths from 0.8–2 mm for color areas.
Color Fill and Brand Impact
Pantone-matched enamel fills, sandblasted backgrounds, or mirror-polished highlights add brand impact. The right finish elevates medals for marathons, brand launches, or public commemorations. Buyers can request custom plating (rose gold, chrome), texture combos, or unique ribbon attachments. Each choice shapes the medal’s first impression.
Zinc Alloy Die Casting for Custom Medals
Choosing zinc alloy die casting means prioritizing precision, endurance, and visual appeal. This process gives buyers control over every aspect: mold detail, relief levels, color separation, anti-corrosion plating, and delivery timeline. Gairun supports clients worldwide in bringing ambitious medal designs to life—whether it’s for a high-stakes sporting event or a unique brand reward. With OEM and ODM service, they’re equipped for complex orders and strict compliance.
- Consistent, repeatable quality in every batch
- Flexible assembly and quick adaptation for new designs
- Durability for medals that last decades
- Branding options that make events memorable
Ordering Process, MOQ, and Compliance
Most die cast medal orders begin at 300 units, though stamping can lower that to 100 for simple designs. Lead times at Gairun range from three to five weeks for die cast medals—allowing mold fabrication, approval samples, plating, and final QA. Every shipment includes full documentation: material certificates, plating QC reports, RoHS/REACH declarations, and AQL sampling results. For medals worn on skin, nickel release testing under EN 1811 ensures comfort and safety.
Packaging Options for Custom Medals
- OPP Bag: Basic, cost-effective for mass events.
- Velvet Box: Premium, ideal for VIP awards.
- Blister Pack: Retail display, high protection.
- Custom Card: Added branding, easy distribution.
Quality Control and Standards in Medal Manufacturing
A medal’s finish and adhesion must pass strict tests. Plating thickness is checked with XRF equipment, adhesion with tape-pull tests (per ASTM D3359), and color with spectrophotometers (ΔE <2 for color difference). Salt-spray testing (per ASTM B117) exposes medals to corrosion for 24–96 hours, simulating years of real use. Hardness is validated by HV readings, and every order meets RoHS/REACH compliance for export. Gairun’s dedication to these details ensures your medals arrive perfect, every time.
Frequently Asked Questions
What is zinc alloy die casting, and why is it used for medals?
Zinc alloy die casting is a process where molten zinc alloy is injected into steel molds under high pressure to make durable, highly detailed medals.
How do die cast medals differ from stamped medals?
Die cast medals feature deeper relief, heavier feel, and sharper edges, while stamped medals are flatter, lighter, and better for basic designs and lower budgets.
What finishing options are available for custom die cast medals?
Finishes include electroplating in gold, nickel, brass, gunmetal, matte black, and add-ons like hard or soft enamel, epoxy domes, and sandblasted textures.
What is the minimum order quantity (MOQ) for die cast medals?
The typical MOQ for die cast medals starts at around 300 pieces; stamped medals may be available in smaller batches of 100 or more.
What are common quality control checks in medal manufacturing?
Tests include plating thickness with XRF, adhesion (ASTM D3359), salt-spray resistance (ASTM B117), AQL sampling, and compliance with RoHS and EN 1811 standards.
Can medals be customized in terms of relief, color, and assembly?
Yes, buyers can specify relief depth (2D/3D), Pantone-matched enamel colors, personalized plating, and special ribbons or packaging options for each medal order.
