The Foundations of Soft Enamel Medals
Soft enamel medals hold a special place in award ceremonies, sporting events, and club achievements. Their vibrant colors and raised metal edges make each piece come alive in the hand. Factories like Gairun use advanced manufacturing processes to bring imagination to life. Every stage, from the metal blank to the final vivid color, demands precision and teamwork.
What Sets Soft Enamel Medals Apart?
Unlike hard enamel, soft enamel medals feature textured, raised outlines with colorful recesses that catch the light. The surface isn’t completely smooth; the colored recesses sit slightly below the metal edges, offering a tactile feel. These medals balance unique aesthetics with practical durability.
Main Uses and Material Choices
- Sports events and marathons
- Corporate recognition awards
- Custom promotional gifts
Zinc alloy is most popular, prized for its strength and moldability. Brass or iron also see use, depending on hardness, cost, or finishing details.
Step-by-Step: How Soft Enamel Medals Are Made in the Factory
The journey begins with design. Artwork arrives as a vector file, laying out every line and color zone. Next, engineering teams transform that vision into a physical mold using wire EDM (electric discharge machining) or CNC routers. This precise tooling ensures sharp details and correct metal depths for color filling later on.
Stamping or Die Casting: Forming Medal Blanks
Most soft enamel medals start with die casting or stamping. Die casting injects molten zinc alloy into a precision mold, capturing 2D or 3D reliefs. Stamping uses powerful hydraulic presses to punch shapes from rolled brass, iron, or stainless steel sheets, ideal for flat profiles. Thickness typically ranges from 2 mm to 5 mm, balancing weight with strength.
Quick Comparison:
| Process | Material | Best for | Finish Quality | MOQ |
|---|---|---|---|---|
| Die Casting | Zinc Alloy | Complex 3D | High | 500+ |
| Stamping | Brass, Iron, Steel | Flat/2D | Good | 300+ |
Deburring and Polishing: Preparing the Surface
After cutting, every blank passes through deburring machines or hand tools to remove sharp edges. Next, tumbling and polishing smooth the surface, eliminating pockmarks and preparing the metal for plating.
Electroplating: Achieving the Perfect Finish
Electroplating gives each medal its metallic sheen. Common finishes include bright gold (Au), antique brass, nickel, matte black, and gunmetal. Plating thickness, usually 5–20 microns, is checked using XRF instruments to ensure corrosion resistance and durability. Gairun selects the exact process—sometimes adding PVD or powder coating—based on the client’s branding and use case.
- Gold plating for high-end sports awards
- Antique brass for vintage aesthetics
- Satin nickel for modern corporate medals
Precision Enamel Color Filling: Where Art Meets Science
With plating complete, artisans move to the heart of the process: enamel color filling. Soft enamel uses colored resin (or pigment-filled synthetic enamel) matched precisely to Pantone codes. Operators deposit each hue by hand or automated dispenser, ensuring the resin fills only the recesses. Each chamber must stay inside the raised metal borders, making steady hands and sharp eyes a must.
- Pantone matching for brand consistency
- Controlled fill depth: usually 0.2–0.3 mm below metal edge
- Multiple colors separated by dams (metal ridges)
Impact of Color Filling on Medal Quality
If color overflows the metal edges, the medal loses sharpness and professional appeal. Underfilling leaves gaps and uneven surfaces. Precision tools, like fine-tipped syringes and digital dispensers, keep production accurate and repeatable. QC inspectors use magnifiers to check for overflows and bubbles, holding each unit to strict standards.
Baking and Curing: Locking in Color
The filled medals enter industrial ovens set at carefully controlled temperatures, often 150–180°C for 10–25 minutes. This stage is critical—too much heat causes color distortion or microcracks, while too little leaves resin soft and uneven. Bake profiles are tailored to each enamel type and medal thickness.
Why Baking Matters
- Ensures chemical bonding between resin and metal
- Prevents fading and color bleed over time
- Hardens enamel for scratch resistance
Technicians monitor oven cycles with data loggers, cross-referencing with color difference values (ΔE) and hardness tests (HV microhardness). If results deviate, the batch is pulled for rework or held for extended curing.
Final Steps: Quality Control and Assembly
After baking, medals cool and undergo intense quality checks. AQL sampling (using ANSI/ASQ Z1.4 standards) ensures a representative batch passes inspections. Key checks include:
- Plating adhesion: checked with ASTM D3359 tape test
- Color accuracy: measured against Pantone swatches (ΔE < 2.0)
- Hardness: confirms durability for wear and handling
- Salt-spray test (ASTM B117) confirms corrosion resistance for outdoor medals
Once cleared, medals receive their final attachments, such as ribbon loops, split rings, or magnetic backs. Packaging varies by customer: OPP bags for bulk orders, velvet boxes for premium awards, or branded blister packs for retail display.
Compliance and Safety: Finishing the Journey
Factories like Gairun prioritize global compliance. RoHS/REACH screening ensures metal finishes are free from hazardous chemicals. EN 1811 nickel release testing is vital for wearable medals, keeping skin safe when in contact. Prop 65 and CPSIA standards are met for medals sold in the U.S.
Precision Matters: The Impact of Production Decisions
Each step in soft enamel medal manufacturing ties directly to performance and business outcomes. A well-stamped blank with consistent thickness lays the foundation for crisp details. Correct plating boosts visual appeal and resists tarnish, protecting brand reputation. Accurate enamel filling and controlled baking lock in color and durability, making every medal worthy of display.
| Stage | Business Outcome | Tolerance/Control |
|---|---|---|
| Stamping/Casting | Consistent shape, cost control | ±0.05 mm |
| Polishing | Visual appeal, safe handling | Surface roughness Ra < 0.8 µm |
| Plating | Brand alignment, corrosion resistance | Thickness: 10–20 µm |
| Color Filling | Brand colors, premium finish | Fill depth ±0.05 mm, ΔE < 2.0 |
| Baking | Durability, color stability | Temperature: ±3°C, HV > 160 |
| QC/Assembly | Market readiness, avoid returns | AQL sample size 0.65% |
Gairun: Expertise in Every Detail
Gairun’s expertise stretches from OEM/ODM design to final assembly. The company’s focus on craftsmanship and reliable B2B service means every order meets tight deadlines and high-quality thresholds. Their process ensures soft enamel medals shine with pride—ready for distribution and display.
Comparing Soft Enamel to Hard Enamel Medals
Choosing between soft and hard enamel medals depends on both aesthetics and function. Soft enamel boasts raised metal borders and a textured finish, ideal for eye-catching visual effects at a modest cost. Hard enamel medals feature a glass-smooth finish; the resin is polished flush with the metal, creating a heavier, more upscale look. Hard enamels often cost more due to extra polishing steps and longer baking cycles. The best choice depends on event prestige, budget, and time frames.
Key Differences at a Glance
- Soft enamel: Vibrant colors, tactile relief, quick lead time
- Hard enamel: Smooth surface, premium feel, extended production
Medal Manufacturing Process Efficiencies
Efficient medal manufacturing boosts client satisfaction and bottom-line performance. Factories streamline processes with automated color filling, multi-batch baking ovens, and rapid AQL quality checks. Automation can cut color filling time by up to 30%, while precise oven controls reduce failure rates. These gains translate to lower cost-per-piece and faster fulfillment, especially for urgent event schedules.
Common Customization Options
- Personalized engraving with laser or CNC
- Custom ribbon colors and attachment styles
- Special finishes — matte, antique, chrome
Applications and Branding Impact
Soft enamel medals do more than symbolize victory. They boost brand recognition, foster team pride, and create mementos that endure. Companies choose unique plating, color combinations, and attachments to align with their image. School competitions, city marathons, and corporate launches all benefit from distinct medal designs.
Expert Takeaway: “Investing in quality color filling and careful baking pays off in durability and lasting vibrancy. Never rush the curing stage; it’s the secret to medals that stand up to wear and show off true colors.”
Medal Manufacturing Cost Factors
Pricing depends on material, size, process, finish, and order quantity (MOQ). Die casting supports detailed design but requires larger runs. Stamping offers economy for flat profiles and lower MOQs. Plating—a key cost driver—varies by metal type and thickness. Color filling also adds to labor and setup fees, especially for multi-color medals.
| Factor | Impact on Cost | Typical Range |
|---|---|---|
| Material | Raw cost, durability | Zinc: $0.25–$0.45/medal |
| Process | Complexity, tooling needed | Die casting: $350+ mold fee |
| Plating/Finish | Premium appearance | Gold: +$0.08–$0.20/medal |
| Color Filling | Labor, setup | $0.10–$0.30/color |
| Packaging | Presentation | Velvet box: +$0.60/medal |
Choosing a Manufacturer for Soft Enamel Medals
Selecting a capable partner ensures project success. Leading manufacturers like Gairun deliver consistency, custom options, and strict QC. Check for:
- Certifications (ISO 9001, RoHS, REACH)
- Responsive sampling process
- Flexible design and material choices
- Reliable lead times and MOQ options
Ask about plating thickness, color matching control, and compliance for overseas orders. These factors shape both medal performance and buyer confidence.
Frequently Asked Questions
What are soft enamel medals?
Soft enamel medals are metal awards featuring raised outlines and colored recessed areas below the surface, creating textured designs.
How do stamping and die casting differ in medal production?
Stamping uses pressed metal sheets for flat medals, while die casting uses molten zinc alloy for more detailed, 3D designs.
Why is precision important in enamel color filling?
Accurate color filling prevents overflow or gaps, ensuring clear designs and maintaining brand color standards and visual appeal.
How does baking affect enamel medals?
Baking hardens the enamel, locks in color, and boosts scratch resistance, preventing fading and damage during use.
What quality checks are performed on soft enamel medals?
Quality checks include plating adhesion, color accuracy, hardness, and corrosion resistance tests, all based on international standards.
Can Gairun customize medal finishes and attachments?
Yes, Gairun offers various finishes, colors, engraving, and mounting styles to create custom medals for different client needs.
