Discovering Custom Metal Medals: Precision for Sports, Military, and Commemoration
Custom metal medals are symbols of achievement, honor, and memory. At Gairun, precision and craftsmanship meet practical needs for sports competitions, military celebrations, and commemorative events. Each medal combines unique design with resilient materials—reflecting the occasion and values they represent.
Types of Custom Metal Medals
The world of custom metal medals is diverse, with styles tailored to every purpose. From athletic triumphs to military service, and events worth remembering, manufacturers like Gairun deliver options that fit your exact requirements. Let’s explore 12 major types:
- Sports Medals: Designed for tournaments, marathons, and championships. Durable and attractive, often featuring 3D elements and vivid enamel colors.
- Military Medals: Used for service awards, bravery honors, and unit identification. Precision-inscribed, often in antique finishes, compliant with EN 1811 nickel standards.
- Commemorative Medals: Mark historic events, anniversaries, and milestones. Custom shapes, dual plating, and colored highlights tell a story.
- Corporate Recognition Medals: Reward employees and partners for outstanding achievements. Branding details, serial numbering, and satin or mirror polishes.
- Academic Medals: Celebrate excellence in education. Refined logos, color separation, and reliable attachment options.
- Club & Association Medals: Unify groups with identity and pride. Custom emblems, split ring mounting, and vivid enamel.
- Marathon & Sport Event Medals: High-relief imagery, Pantone-matched colors, and robust zinc alloy for endurance.
- Memorial Medals: For funerals or historical remembrance. Subtle finishes, engraved names, and secure packaging.
- Festival & Cultural Medals: Capture spirit of parades or local feasts. Diverse shapes, intricate casting, and themed colors.
- Custom Coin Medals: Merge coin styling with recognition. Often dual-sided, ideal for clubs and collectors.
- Brand Promotion Medals: Elevated corporate image with unique metal crafts. Durable branding and flexible MOQ.
- Decorative Medals: Gifts, souvenirs, or membership tokens. Creative finishes and easy custom packaging.
Material Choices for Custom Metal Medals
The right material boosts medal durability and visual appeal. Here’s a comparison of popular options used by Gairun:
| Material | Cost | Tolerance | Finish Options | Best Use |
|---|---|---|---|---|
| Zinc Alloy | Mid | ±0.10mm | Antique, matte, plated | 3D/fine relief, sports, branding |
| Brass | High | ±0.06mm | Mirror, brushed, gold plated | Military, awards, classic medals |
| Stainless Steel (304/316) | Mid-High | ±0.06mm | Satin, mirror, laser etch | Endurance, outdoors, commemorative |
| Iron/Steel | Low | ±0.20mm | Nickel, black, painted | Budget, large volumes, simple shapes |
| Aluminum (6061/5052) | Mid | ±0.10mm | Anodized, color, lightweight | Lightweight, kids’ events, festivals |
Material Selection: Factors to Consider
- Application: Sports medals need impact resistance; military awards need corrosion resistance.
- Budget: Brass costs more but shines with heritage; iron offers volume savings.
- Finish: Zinc alloy accepts fine platings; aluminum lends vibrant anodized colors.
- Thickness: Ranges from 1.5mm (light medals) to 5mm (deeply cast, high-relief pieces).
Manufacturing Processes Behind Custom Metal Medals
How each medal takes shape depends on the chosen process. Manufacturers like Gairun employ these core techniques:
Die Casting
Heated zinc alloy or brass is injected into high-precision molds formed by wire EDM. This creates detailed 2D or 3D reliefs. Most sports and commemorative medals use die casting, allowing for deep finish textures.
Stamping / Pressing
Sheets of iron, steel, or brass are pressed between dies. This method suits simpler, budget-friendly medals. It delivers crisp edges and ensures strong attachment points.
Photo-Etching
A chemical process etches intricate designs onto flat metal surfaces, ideal for light medals like badges or nameplates. It allows high resolution for detailed logos and text.
CNC Milling / Turning
Computer-controlled machines slice and carve metal blanks with precision. This suits small batch, high-detail orders, especially custom commemorative coins and unique military medals.
Deburring, Tumbling, and Shot Blasting
Post-shaping, medals undergo deburring to smooth edges, tumbling for uniform texture, and shot blasting for enhanced surface appeal. These steps are essential for comfort and safety in wearables.
Coloring and Relief Techniques for Medals
Color adds emotion and importance to custom metal medals. Mastering color fill and relief yields lasting impact:
Enamel (Soft and Hard)
Enamel is a colored powder melted onto the medal’s surface. Soft enamel sits below the metal ridges, creating tactile surfaces. Hard enamel is polished smooth and flush, yielding a premium, glass-like finish. Both allow Pantone-matching and fill depths down to 0.2mm.
Epoxy Dome
A transparent epoxy coating covers enamel or printed graphics, protecting colors from scratches and corrosion. This method enhances glossiness and durability.
Relief (2D vs. 3D)
- 2D Relief: Medals feature flat surfaces with layered depth—perfect for logos and simple imagery.
- 3D Relief: Medals show rounded, sculpted shapes. Ideal for lifelike portraits and dynamic actions (e.g., runners, eagles).
Finishing Options: The Final Touch
Finishes define a medal’s character and lifespan. Gairun employs strict tolerance and adhesion checks, using plating thickness tests (XRF) and ASTM D3359 standards for enamel adherence. Choose from:
- Electroplating: Antique brass, nickel, gunmetal, matte black, gold, rose gold, chrome.
- Anodizing (Aluminum): Durable color, satin or matte texture.
- PVD (Physical Vapor Deposition): Extra hard coatings for elite military or collectible medals.
- Powder Coating: Deep, lasting colors with sandblasted texture.
- Brushed, Mirror, Satin Finishes: Each suited for branding, visibility, or tactile feedback.
Expert Takeaway: “Choosing finish isn’t just about looks—it controls corrosion resistance, tactile feel, and long-term value.”
Assembly, Mounting, and Packaging Choices
How the medal attaches and arrives makes a difference for end-users. Gairun offers:
- Split Rings & Lobster Clasps: For secure, easy wear on ribbons or chains.
- Butterfly Clutches & Magnetic Backs: Ideal for lapel pins and lightweight medals.
- Rivets & Screw Posts: Heavy-duty mount for military or ceremonial medals.
- Packaging: Choose OPP bags (budget), velvet boxes (premium), blister cards (retail), or custom cards (branding).
Label & Compliance Details
Every medal intended for wear must pass EN 1811 nickel release tests to avoid skin allergies. For markets in the US, Gairun follows CPSIA and Proposition 65 measures. Color difference (expressed as ΔE) and plating thickness (in μm) are documented for B2B clients.
Quality Assurance in Medal Manufacturing
Durability and consistency keep custom metal medals looking their best. Gairun’s in-house QA uses AQL sampling (ANSI/ASQ Z1.4), salt-spray corrosion tests (ASTM B117), and hardness checks (HV rating). These ensure medals survive rough handling, outdoor storage, and frequent display without losing appearance or integrity.
Applications: Sports, Military, and Commemorative Use Cases
Custom metal medals shine in distinct settings:
- Sports Events: Marathons, matches, and championships demand impact-resistant, attention-grabbing medals.
- Military Functions: Service awards, retirement honors, and unit identities rely on lasting, prestigious metals.
- Commemorative Ceremonies: Historic anniversaries, memorials, and fundraisers need unique shapes, stories, and finishes.
- Corporate Milestones: Mark team achievements and brand anniversaries with custom motifs.
- Club & Association Gatherings: Foster unity and pride through symbolic, collectible medals.
Custom Metal Medals: Buyer’s Guide
Securing the right medal starts with a clear brief. Consider these checklist items:
- Design Files: Vector artwork (.AI, .SVG) for sharp, scalable output.
- Material Choice: Match performance needs with budget and look.
- Finish & Color: Define plating, enamel colors, and logo placement.
- Mounting & Packaging: Pick attachment type and retail display option.
- MOQ & Lead Time: Clarify minimum order quantity and target delivery date.
Gairun’s OEM/ODM services simplify the journey from concept to delivery, handling mold development, sampling, plating, and bulk logistics for B2B clients worldwide.
Frequently Asked Questions
What materials are best for sports custom metal medals?
Zinc alloy and brass are popular for sports medals because they offer durability, fine relief, and support vibrant enamel colors. These metals also resist wear during active use.
How is color added to custom metal medals?
Color is typically added using soft or hard enamel fills, with options for Pantone matching. For extra protection, an epoxy dome or powder coating may be applied after coloring.
Can custom metal medals be made in both 2D and 3D relief?
Yes. Most manufacturers, including Gairun, offer medals in both 2D (flat layers) and 3D (sculpted shapes) to suit logos, portraits, and action scenes.
What finishes are available for custom metal medals?
Finishes include antique brass, matte nickel, gunmetal, gold, rose gold, chrome, anodized colors, PVD, brushed, mirror, and satin. The choice impacts medal aesthetics and corrosion resistance.
How are custom metal medals tested for quality?
Quality tests involve plating thickness checks (XRF), adhesion (ASTM D3359), salt-spray resistance (ASTM B117), and hardness (HV). Finished medals are sampled following AQL standards for defects.
What is the minimum order quantity for custom metal medals?
MOQ depends on the process and material, but Gairun typically supports small trial orders starting from 100 pieces, with bulk pricing for larger quantities.
