Mould Making for Zinc Alloy Medals: Why Good Tooling Saves You Money
Choosing the right mould making process for zinc alloy medals does more than shape your product—it protects your budget, your brand reputation, and your ability to deliver consistency at scale. High-quality tooling delivers cleaner details, faster production, and fewer hidden costs in the long run. Smart manufacturers know that investing up front in top-tier die casting moulds and medal tooling can be the difference between flawless medals and expensive surprises.
Understanding Mould Making for Medals
A mould is a custom tool used to shape molten metal into the precise form of your medal or coin. In zinc alloy medal production, the mould defines every detail, from surface texture to edge crispness. Each design—whether for a limited edition marathon award or a corporate commemorative coin—starts with a carefully engineered mould.
The Types of Moulds Used
- Die Casting Moulds: These are steel blocks machined to include your design’s negative. Suitable for high-volume runs, they offer optimum strength and resists wear.
- Silicone/Rubber Spin Casting Moulds: Used for small batches or complex shapes, but less durable for production runs.
For most zinc alloy medals, die casting moulds crafted from steel deliver the best performance and cost efficiency over time.
How Die Casting Moulds Are Made
Creating a die casting mould is a precise process that combines digital design, precision machining, and skilled finishing. Here is a typical workflow:
- 3D Design Modeling: CAD software translates your artwork into a 3D model, detailing every mm of relief, logo text, and border.
- CNC Machining: High-speed CNC (Computer Numerically Controlled) mills and wire EDM (Electrical Discharge Machining) carve your design into hardened steel. These methods allow for razor-sharp lines and controlled tolerances as fine as ±0.02 mm.
- Engraving and Finishing: Skilled technicians manually touch up undercuts and ultra-fine details, adding depth for sharp 2D or 3D relief. Texture plates may be applied to mimic sandblasted, mirror, or brushed finishes.
- Inspection and Testing: Each mould cavity is tested for accuracy using CMM (Coordinate Measuring Machines) and sample-cast runs, ensuring defects like underfill or flash are eliminated before full production begins.
Why Surface Detail Matters
The better the surface finish and precision of your mould, the more striking and durable your medals. Intricate text, sharp logos, and defined relief all depend on this foundation. High-quality moulds also mean fewer defects per batch, easier color separation (for soft or hard enamel), and more uniform plating thickness during finishing.
Mould Making for Zinc Alloy Medals: Why Good Tooling Saves You Money
At first glance, the expense of a premium die casting mould for medals can seem high. Buyers often wonder why these costs are justified, and what payback they can expect. The answer: good tooling pays for itself through lower scrap rates, cleaner surfaces, faster cycle times, and consistent product quality across thousands—or even hundreds of thousands—of pieces. Gairun, renowned for its precision OEM/ODM medal tooling, has seen clients recoup initial tooling investments in as little as one high-volume event or recurring contract order.
Direct Impact on Cost Per Medal
- Less Rework and Lower Scrap: Precision tooling delivers medals with fewer surface imperfections, reducing hand finishing and rejections.
- Longer Tool Life: Hardened steel moulds often last 50,000 to 500,000 shots, lowering cost per unit on large orders.
- Shorter Production Times: Smooth, well-ventilated moulds let metal flow efficiently, which means lower labour and energy costs per batch.
Why Tooling Quality Drives Medal Appearance and Consistency
In medal production, even small mould faults can destroy a run: blurred lettering, uneven relief, or plating pitting. Top tooling sharpens every feature—essential for 2D and 3D custom relief. With proper cavity venting and polish, the molten zinc alloy fills every detail, avoiding cold shuts or weld lines. After casting, smooth mould surfaces speed up deburring, tumbling, and shot blasting. This means more units pass quality control, keeping your supply chain on track for deadlines.
Surface Finish and Relief Control
Gairun engineers finishes ranging from bright mirror to antique sandblast by adding surface patterns directly in the mould. Consistent finish starts at the mould stage, reducing need for manual adjustment.
See the comparative chart below for how mould precision affects outcome across key variables:
| Factor | Premium Die Casting Mould | Low-Quality Mould |
|---|---|---|
| Surface Detail | Sharp relief, fine texture, crisp fonts | Blurry edges, rough grain, distortion |
| Tolerances | ±0.02 mm | ±0.10 mm or higher |
| Longevity | Up to 500,000 casts | Below 20,000 casts |
| Plating Consistency | Uniform thickness | Patchy, uneven plating |
| Post-Processing | Minimal clean-up required | Extra hand-sanding, more rejects |
| Cost Per Medal | Lowers as quantity increases | Fluctuates due to waste |
Common Questions About Mould Cost, Lifetime, and Re-orders
Let’s clear up the most frequent questions metal craft buyers ask when investing in new medal tooling:
How Is the Cost of a Medal Mould Calculated?
Mould cost depends on size, complexity, relief depth, and the number of cavities (how many medals produced per shot). More complex designs or deeper 3D require more CNC and handwork. Typical die casting moulds for medals range from $350 to $2,000, depending on requirements. These are usually a one-time charge unless a design update is needed.
What Is the Lifetime of a Medal Mould?
Hardened steel moulds for zinc alloy can last from 50,000 up to 500,000 shots. Factors affecting lifespan include alloy type, relief complexity, and maintenance. Gairun tracks mould usage for customers and advises on re-polishing or refurbishment when needed to maintain output quality.
Can I Re-order Medals Without Paying for a New Mould?
Yes, if you re-order the same design, your mould is stored and reused at no extra cost, apart from possible maintenance if extensively used. It’s smart to confirm yearly mould storage and maintenance terms with your supplier upfront.
What Happens if My Mould Wears Out?
Moulds with worn cavities will show relief loss or casting defects. Re-polishing can often extend life, but a new tool may be needed for very high volumes. Reliable vendors, like Gairun, always notify clients if a tooling refresh is due before defects impact product quality.
The Real-World Process: From Artwork to Finished Medal
Turning your artwork into a finished zinc alloy medal involves coordinated work at every step. Here’s what happens in a typical project:
- Artwork Preparation & Approval: Designers check your file for feasibility and convert to a mould-ready CAD file, optimizing for 2D or 3D relief and color separation.
- Mould Fabrication: CNC and EDM machines create steel dies, then skilled technicians deepen or engrave features for extra clarity.
- Sample Casting: The first cast checks dimensions, surface finish, and relief accuracy. Samples may undergo soft or hard enamel filling, then electroplating to verify color and texture.
- Full Production Run: After approval, medals are die-cast, filled or varnished (if required), plated, and assembled (ribbons, boxes, or carded packs).
- Quality Assurance: Measurements (for tolerances), plating thickness checks (using XRF), hardness tests, and salt-spray resistance are validated against standards like ASTM B117 and RoHS/REACH regulations. Inspection often follows AQL methods from ANSI/ASQ Z1.4.
Key Factors That Influence Medal Tooling Cost
Many variables play into the final cost of a medal mould. Smart buyers look out for these:
- Mould Size and Shape: Larger and thicker medals need more steel and longer machining time.
- Relief and Detailing: Complex 3D relief or small font text requires finer cutters and manual engraving—both increase cost.
- Cavities Per Mould: More cavities mean higher initial cost but can dramatically lower cost-per-unit in mass production.
- Surface Finish: Special textures (such as sunray, brushed, or sandblasted) may require additional tool inserts or pattern plates.
- Expected Volume: For large, repeated orders, investing in a premium or multi-cavity die pays off handsomely.
Hidden Savings of High-Quality Moulds
“A top-quality die casting mould isn’t just about first impressions—it means less downtime, fewer defects, and reliable delivery for every order.”
By asking about tool steel grade, CNC/EDM precision, venting, and guaranteed tool life, buyers can avoid mid-order headaches and ensure medals arrive on time and on spec.
Die Casting Mould Maintenance and Storage
After production, proper cleaning and coating with protective oil prevents corrosion and extends tool life. Responsible suppliers log usage and perform preventative maintenance, ensuring moulds are always ready for re-orders. Ask about re-polishing or refurbishment options, especially after large event runs.
How Material, Finish, and Relief Affect Medal Tooling
The type of zinc alloy (most common: Zamak 3 or Zamak 5), desired relief (2D or 3D), and finish (antique brass, gunmetal, gold, nickel) all determine how your medal tooling is designed. Harder alloys require slightly looser tolerances. Deep 3D requires deeper cavities and better venting. Soft or hard enamel color areas need precise cavity depth control for even fill. Electroplated finishes demand smooth steel surfaces in the mould.
Applications and Brand Impact
- Marathons and sports events: eye-catching, durable medals that withstand handling and humidity.
- Corporate or brand awards: consistent finish and sharp logos that reinforce brand trust.
- Collectors’ series and coins: precision detail for visual impact and tactile appeal.
Why Partner with Experienced Medal Tooling Experts?
Entrusting your medal project to an experienced manufacturer like Gairun means more than access to precision machinery. Their metal craftsmen provide critical advice on material choice, finish, relief moldability, and quality assurance sampling. This partnership ensures your medals aren’t just beautiful—they’re reliable, within tolerance, and ready for international shipment without worry.
From Design to Delivery
The right supplier will assist from digital proofing and Pantone color matching to assembly choices (ribbons, split rings, custom packaging). With in-house die casting, stamping, and plating lines, Gairun supports orders ranging from 500 to 500,000+ units per year, keeping MOQ, lead time, and finish quality under your control.
Your Next Steps
- Gather your design files and desired specs (size, finish, ribbon/pack choice).
- Request a clarity on tooling charge, production sample process, and storage/maintenance policies.
- Review technical drawings and confirm relief, color, and plating specs.
- Trust your project to a vendor with in-house tooling and quality control (not outsourcing critical steps).
Thinking ahead on your next event or branded recognition program? Investing in high-quality die casting moulds for zinc alloy medals is the surest way to save on every order—and keep your awardees delighted.
Frequently Asked Questions
What is the typical mould making process for zinc alloy medals?
The process includes digital design, CNC machining, manual engraving for details, and testing with sample castings to ensure accuracy and surface quality.
How much does a die casting mould for medals cost?
Mould costs range from $350 to $2,000 based on size, complexity, and number of cavities required for your design.
How long can a high-quality medal mould last?
A well-made steel die casting mould can produce between 50,000 and 500,000 medals with proper maintenance.
Do I need to pay for a new mould with every reorder?
You only pay once for the initial mould unless your design changes; maintenance is typically covered for standard use reorders.
What maintenance is required for medal moulds?
Regular cleaning, anti-corrosion oiling, and occasional re-polishing extend mould life and preserve medal detail quality.
How does mould quality influence final medal appearance?
High-quality moulds deliver sharper relief, cleaner surface textures, and more consistent plating, reducing defects and saving time downstream.
