Solid metal medals are prestigious awards that symbolize achievement, honor, and excellence. Their durable construction, polished appearance, and significant weight make them a preferred choice for sports competitions, corporate recognition, and special ceremonies. But have you ever wondered how these impressive medals are made?

In this article, we’ll explore the step-by-step manufacturing process of solid metal medals, from the selection of materials to the final polishing and customization.

Step 1: Material Selection

The foundation of every solid metal medal is the material used. Manufacturers typically choose metals such as brass, bronze, copper, zinc, or stainless steel, depending on the desired finish, weight, and durability. Each metal has unique properties:

• Brass: Offers a gold-like appearance and is highly resistant to tarnishing.

• Bronze: Known for its durability and elegant brownish hue.

• Copper: Provides a warm, reddish tone, ideal for unique designs.

• Stainless Steel: Durable and resistant to corrosion, perfect for long-lasting awards.

The choice of metal also impacts the cost and ease of processing, making it a critical first step in medal manufacturing.

Step 2: Design and Prototyping

Before production begins, the medal’s design is finalized. Designers use computer-aided design (CAD) software to create detailed sketches, including dimensions, textures, and engravings. The design may include intricate elements like logos, text, or images to reflect the event or occasion.

Once the design is approved, a prototype or mold is created. This mold is a key tool for the manufacturing process and ensures consistency across all medals produced.

Step 3: Metal Casting or Stamping

The next step is shaping the medal, which can be done through casting or stamping:

• Casting: In this process, molten metal is poured into the mold and left to cool and solidify. This method is ideal for complex, three-dimensional designs with fine details.

• Stamping: A sheet of metal is pressed into the mold using a high-pressure stamping machine. This technique is faster and more cost-effective for flat or simple designs.

For solid metal medals, casting is often preferred due to the need for depth and precision.

Step 4: Trimming and Shaping

Once the raw medal is formed, it undergoes trimming to remove excess metal or imperfections around the edges. This is typically done using CNC machines or hand tools to ensure clean, precise edges.

Shaping may also include adding grooves or ridges to enhance the medal’s design, giving it a more refined look.

Step 5: Polishing and Surface Finishing

After shaping, the medal’s surface is polished to achieve a smooth, shiny finish. This step involves using polishing machines and abrasives to remove any scratches or roughness.

For aesthetic appeal, manufacturers apply surface finishes such as:

• Electroplating: Adds a layer of gold, silver, or another metal for a premium appearance.

• Antiquing: Gives the medal a vintage look by darkening certain areas to create contrast.

• Brushing: Produces a matte or satin finish for a subtle elegance.

The choice of finish depends on the desired look and feel of the final product.

Step 6: Engraving and Customization

Customization is a crucial aspect of making solid metal medals unique. Using techniques like laser engraving, embossing, or etching, manufacturers add personalized details such as:

• Names of recipients.

• Event titles and dates.

• Logos or emblems.

Advanced laser engraving ensures precise and permanent details, enhancing the medal’s overall appeal.

Step 7: Attachment of Ribbons or Accessories

Most medals are designed to be worn or displayed, so ribbons or other accessories are attached at this stage. A small loop or hole is often integrated into the medal’s design for easy ribbon attachment. Ribbons can also be customized to match the event’s theme or branding.

For medals meant for display, stands or cases may be provided to showcase the award.

Step 8: Quality Control and Packaging

Before shipping, each medal undergoes thorough quality control checks to ensure it meets the required standards. Inspectors examine the medals for:

• Surface defects, such as scratches or uneven finishes.

• Accuracy of engraved details.

• Proper attachment of ribbons or accessories.

Once approved, the medals are carefully packaged to prevent damage during transportation. Many manufacturers offer custom packaging options, such as branded boxes or protective cases.

The Significance of Craftsmanship

The manufacturing of solid metal medals combines advanced technology with skilled craftsmanship. While machines handle precision tasks, experienced artisans often oversee critical stages, such as polishing and engraving, to ensure a flawless finish. This blend of technology and artistry is what makes solid metal medals stand out as timeless symbols of achievement.

The production of solid metal medals is a meticulous process that involves multiple stages, from material selection to final packaging. Each step is designed to ensure that the medals not only look stunning but also stand the test of time. Whether you’re awarding participants in a sports event, recognizing corporate milestones, or celebrating academic excellence, solid metal medals offer a durable and elegant way to honor achievements. With their combination of durability, customization options, and aesthetic appeal, these medals truly embody the spirit of excellence and recognition.