Project Kickoff: Understanding Your Medal Design Goals
The journey begins with clear communication. A strong brief is the foundation for a smooth custom medal design process. At this stage, your manufacturer will discuss creative ideas, practical needs, and technical limitations. Gairun, for example, assigns dedicated project managers who ask the right questions to clarify every detail.
- Purpose & Event: Define the purpose—marathon finishers, academic achievements, brand promotion, or other uses.
- Design Preferences: Share inspiration images or sketches. Specify shapes (round, custom outline), size, and weight targets.
- Budget & Timeline: Outline your budget constraints and need-by date. This shapes choice of materials, finishes, and processes.
- Recognition Levels: Are multiple versions needed (gold/silver/bronze, different divisions)?
- Packing & Presentation: Specify packaging preferences, such as velvet boxes or eco-friendly bags.
A thorough intake helps pre-empt problems and ensures your project stays on track.
Medal Artwork Preparation: File Guidelines & Best Practices
Once the brief is set, it’s time to submit your artwork. Providing clear, high-quality files helps ensure that every detail turns out as you expect. Most factories will accept:
- Vector files: AI, EPS, or PDF are preferred, as they allow for precision scaling and color separation during production.
- High-res images: 300 dpi PNG, JPG, or TIFF files are accepted if vector artwork is unavailable, but may require redrawing.
- Font files: If your medal includes specific typography, attach font files or outline all text in vectors to avoid font substitution errors.
- Pantone (PMS) color codes: Use PMS codes to specify exact enamel or print colors.
If you only have a rough sketch or logo, experienced medal makers like Gairun offer in-house art refinement. Their designers provide free digital mockups and recommendations on relief (2D vs. 3D), color placement, and textures to optimize the artwork for manufacturing processes.
3D Modeling and Digital Proofs: Bringing Artwork to Life
With finalized artwork, the factory’s designers convert your design into a detailed production-ready format. This step usually involves creating a 3D model using CAD (computer-aided design) software if your medal features sculpted or multi-level elements. For flat designs, a layered vector file may suffice.
- 3D CAD modeling. Converts the design into a technical drawing with precise depth specifications (often measured in millimeters). This stage defines elements such as raised logos, sunken backgrounds, and contour lines.
- Digital rendering. Produces lifelike previews showing how metal finishes, enamel colors, and ribbon attachments will look.
- Approval. You’ll receive the rendered artwork for comments or approval before mold making begins.
Timely feedback at this stage is crucial—any change here is low-cost, while changes after mold production become expensive.
Mould Making: Transforming Design Into Industrial Reality
Once you approve the 3D model, the production team creates a custom steel mold. This is a critical investment in the custom medal design process, especially for complex or high-volume projects. Moulds are fabricated with precision—often using CNC milling or wire EDM for high-detail edges and 3D surfaces.
Mould Making Steps
- Material selection: Durable steel alloys ensure mold longevity.
- CNC engraving: High-speed tools cut intricate shapes and reliefs into the mold block.
- Hand finishing: Skilled technicians polish and refine the cavity for crisp detail transfer.
- Trial pressing: The mold is tested with soft material (like wax or lead alloy) to check details before mass production.
Revisions made here, such as deepening text or smoothing edges, are much easier and cheaper than after serial production starts.
Trial Samples: The Importance of Pre-Production Proofs
After mold approval, a small run of trial medals is produced. These pre-production samples are vital checkpoints of the custom medal design process. They confirm that artwork, color fills, relief, and attachment hardware look and feel exactly as intended.
| Aspect | Trial Sample | Mass Production |
|---|---|---|
| Unit Cost | Higher (setup + labor) | Lower (economies of scale) |
| Turnaround | 5–10 days | 3–4 weeks (quantity dependent) |
| Finish | Manual touch-up | Machine standardization |
| Purpose | Final approval, marketing photos | Bulk fulfillment |
What Customers Should Review in Samples
- Metal finish (e.g., antique brass, shiny gold, matte nickel)
- Color accuracy vs. Pantone references
- Clarity of text, logos, and relief depth
- Attachment style (ribbon slot, loop, or custom fitting)
- Weight and overall feel
Once you approve the sample, production scales up with your signoff documented for quality assurance.
Custom Medal Design Process
This centerpiece section brings every stage together. Below is a step-by-step workflow, highlighting both what the customer provides and how a well-organized manufacturer, such as Gairun, communicates at every phase.
- Design Brief & Consultation: You share your event requirements, sample visuals, and preferred specifications. Gairun responds with feasibility analysis and estimated costs.
- Artwork Submission: You send vector files or high-res images. If needed, Gairun’s designers reformat or enhance them to suit manufacturing methods.
- 3D Modeling & Rendering: Gairun creates technical CAD drawings and digital previews for your review and approval.
- Mould Making: Once the digital model is approved, Gairun engineers fabricate a precision steel mold, followed by test pressing.
- Trial Sample & Approval: You receive physical samples, sometimes alongside detailed photos or videos if remote. Approve or suggest changes.
- Mass Production: After approval, Gairun schedules automated die casting or stamping, surface grinding, color filling, and plating for the full order.
- Quality Assurance & Packing: Every batch is inspected for surface quality, plating thickness, adhesion (using standards such as ASTM D3359), and color consistency (ΔE check vs. standard). Gairun adheres to AQL sampling and regulatory requirements like RoHS and EN 1811 for wearable items. Medals are packaged for protection and presentation as specified in your order.
- Delivery & Post-Sale Support: Tracking information and documentation accompany your shipment. Gairun remains available for any post-delivery feedback or warranty questions.
Communication Milestones
- Initial proposal and artwork proofing
- 3D model and mold design confirmation
- Sample approval check-in
- Mass production update
- Quality inspection and shipping notification
Material Choices: Selecting the Right Metal for Your Medals
Each metal brings unique properties to your custom medal. Your manufacturer will advise based on budget, design complexity, and durability needs.
| Material | Best For | Pros | Cons |
|---|---|---|---|
| Zinc Alloy | 3D or high-relief shapes, mid-high volume | Low to medium cost, easy casting, crisp detail | Not as weighty as brass or steel |
| Brass | Premium medals, fine surface work (engraving) | Rich luster, durable, classic feel | Higher cost, heavier |
| Iron/Steel | Flat stamped medals, big volumes | Strong, economical, good for 2D designs | Limited 3D capability, rust-prone if unplated |
| Aluminum (6061) | Large, lightweight medals | Resists corrosion, can be anodized in colors | Softer, doesn’t feel as premium as brass |
| Stainless Steel (304/316) | Eco medals, harsh environments | Rustproof, hypoallergenic, slick finish | Expensive tooling, usually laser cut or engraved |
Thickness typically ranges from 2 to 5 mm. Thicker medals feel more substantial, but increase both cost and shipping weight. Your manufacturer helps you balance these trade-offs for the intended application and budget.
Surface Finishing and Color: Bringing Medals to Life
Surface finish has a huge impact on both first impressions and long-term durability. Some of the most common electroplated options include antique brass, bright gold, matte black, nickel, gunmetal, and chrome. Aluminum can be anodized in vivid hues, while powder coating adds rugged, opaque color layers.
Color Fills & Relief Options
- Soft enamel: Color sits below the metal edges, yielding a tactile finish; protected with optional epoxy dome for extra sheen.
- Hard enamel (cloisonné): Color is ground flush with the metal, giving a gloss-smooth surface and excellent wear resistance.
- 2D relief: Raised and recessed areas on a single plane—ideal for logos and text.
- 3D relief: Sculpted topography, best for faces, mascots, or scenery.
Pantone color matching ensures your brand palette transfers accurately to the medal’s final look. Gairun routinely supplies digital or physical swatches for strict approvals, and controls fill depth to within ±0.05 mm for hard enamel.
Attachment and Packaging Solutions
The right attachment depends on the occasion and how recipients will wear or display the medal. Common options include split rings, ribbon loops, magnetic backs, and screw posts. Gairun also sources custom woven ribbons with your logo or event name dyed in.
Popular Packaging Styles
- OPP or poly bags: Simple, economical protection for shipping
- Velvet box: Premium presentation for VIP awards
- Cardboard blister: Visibility for retail or merchandising
- Custom printed card: Tells your story alongside the medal
Factory teams check that every medal is scratch-free, correctly assembled, and safely packed for transit. Packaging choice can enhance perceived value and brand recognition at the moment of presentation.
Quality Control and Compliance
Before shipment, each order undergoes strict quality checks. Gairun inspectors use digital calipers for dimension and thickness, and verify plating thickness with XRF tests to meet micron targets. Adhesion is measured with tape tests (ASTM D3359), and color difference is tracked using spectrophotometers (ΔE standards).
Salt-spray testing confirms corrosion resistance for outdoor or marine event medals. For wearables, nickel release is checked under EN 1811 to prevent skin allergies. All products are AQL-inspected and RoHS/REACH compliant to meet global safety benchmarks. Gairun documents each inspection and provides photo reports as needed.
Frequently Asked Questions
What type of artwork is best for custom medal production?
Vector files like AI or EPS are ideal as they scale without loss. High-res images can work but may need redrawing for precise detailing during medal production.
How long does the full custom medal design process take?
Most projects require 4–6 weeks, including artwork confirmation, mould making, sample approval, mass production, and international shipping.
Can I make changes after the mould is produced?
Major changes after mould creation are costly, so ensure all design details are approved during the digital artwork and modeling stages.
What is the minimum order quantity (MOQ) for custom medals?
Typical MOQs start around 100–300 pieces, but may vary depending on design complexity, material, and finishing choices.
How are colors matched on medals?
Factories use Pantone (PMS) codes for precise color fills, with digital or physical proofs provided for your approval before bulk production.
Does Gairun offer compliance and safety testing for medals?
Yes, Gairun performs plating thickness, adhesion, salt-spray, and nickel release testing to meet RoHS, REACH, EN 1811, and client-specific safety standards.
