How Custom Medals Are Made
A behind-the-scenes look at our complete 12-step manufacturing process — the same process trusted by Disney, BAA, and event organizers in 50+ countries.
Complete Manufacturing Process
Every MedalOrigin medal goes through 12 precision stages. Our factory in Huizhou, Guangdong handles every step in-house — no outsourcing means faster turnaround and consistent quality.
Design & Artwork
Our design team works from your concept, logo, or reference image using Adobe Photoshop, Illustrator, or CorelDRAW. Every design includes 3D renderings so you can preview your medal from every angle before production starts. Turnaround: 24 hours. Free. Unlimited revisions.
Mold Making
The design is converted into a 3D mold using Beijing Jingdiao CNC software. The mold is carved from mold steel and consists of: mold frame, mold core, support pillars, sliders, ejector pins, and water inlet. Spark erosion creates the matte surface texture on medal surfaces. Heat treatment increases mold hardness and wear resistance.
Die-Casting (Zinc Alloy)
Zinc alloy ingots are melted at 385°C (725°F) and injected into the mold under high pressure using an 88-ton die-casting machine. Zinc alloy (density 6.7 g/cm³) flows exceptionally well, enabling intricate 3D details and openwork (hollow) designs. Minimum wall thickness: 2mm. The four water inlets on round medals are evenly spaced for uniform filling.
Deburring & Polishing
After casting, the medal goes through water gate removal and edge trimming. Then it enters our wet-type eco-friendly polishing machine for surface finishing — first the edges, then the face. Polishing prepares the surface for electroplating and ensures a flawless finish.
Riveting & Assembly
Attachment hardware is riveted onto the medal body: spur pins, safety pins, or simple pins depending on your design. This is also where connecting rings (D-rings, dog clips, jump rings) are attached for ribbon mounting.
Surface Treatment — Electroplating
The most critical aesthetic step. The polishing oil is removed, then the medal goes through ultrasonic cleaning, followed by alkaline copper plating (~500 seconds) as a base layer, acid copper plating (20-60 minutes) for gloss enhancement, then final color plating. Available finishes: gold (imitation), silver (nickel), copper, rose gold, chrome, black nickel, platinum (white gold), matte variants of all colors, and antique finishes (antique gold, antique silver, antique copper, matte black). Special: rainbow vacuum plating and two-tone plating (gold + nickel most common).
Color Filling — Enamel
Our most versatile decoration step. Options include: Soft Enamel (thin paint with recessed metal lines, 0.3mm minimum fill width), Imitation Hard Enamel (thick paste, smooth surface flush with metal lines, 0.5mm minimum), Glass/Translucent Enamel (glossy, semi-transparent), Glitter (sparkle powder applied to semi-dried enamel), Glow in the Dark (luminous powder added after enamel curing). Baking parameters: low temp 60-70°C for 60-90 min (semi-cure), high temp 100°C for 60 min (full cure). Pantone color matching available.
Printing
For designs requiring gradients, fine text, or photographic detail: UV Printing (4-color, flat + 3D surfaces up to 7mm height difference, instant drying), Offset Printing (highest quality on flat surfaces, requires plate fee), Silkscreen Printing (spot colors, extremely precise registration, higher cost), Pad Printing (works on uneven surfaces, low setup cost). Sticker/Photodome option available for budget-friendly full-color on flat areas.
Laser Engraving
For variable data like sequential numbering, participant names, finish times, or custom messages. Laser engraving works on various surfaces and provides permanent, precise marking.
Final Assembly
Magnets (2-20mm diameter), accessories, and custom ribbons are attached. Ribbons are joined using ultrasonic welding or sewing (4-fold, 3-fold, or bias-cut with jump ring). Standard ribbon size: 860-900mm × 20-30mm for adults, 800mm × 20mm for children.
Quality Control
Our three-stage QC process inspects every batch: incoming material inspection, in-process production checks, and final pre-shipment inspection. Common defect checks: cracks (ejector pin issues), water marks (mold or pressure problems), air holes (poor mold venting), plating bubbles (insufficient cleaning), enamel impurities (spray booth cleanliness), and paint pinholes (moisture in compressed air).
Packaging & Shipping
Each medal is individually packaged per your requirements: PP/OPP bags, zip-lock bags, velvet pouches, paper cards, paper boxes, velvet boxes, acrylic cases, or blister packs. Bulk orders are palletized and shipped to 50+ countries worldwide.
Questions About Our Process?
We're happy to walk you through any stage in more detail. Your medals are only as good as the process behind them.
Ask About Our Process