Medal Materials Guide
Choosing the right material is the foundation of a great medal. Compare all five materials we work with and find the best fit for your project and budget.
Material Comparison
| Material | Density | Process | Min. Thickness | Relative Cost | Best For |
|---|---|---|---|---|---|
| Zinc Alloy | 6.7 g/cm³ | Die-casting | 2mm | $$ | 3D details, openwork, complex shapes, most popular |
| Brass | 8.9 g/cm³ | Stamping+Cutting | >3mm hard | $$$ | Premium weight, military medals, challenge coins |
| Iron | 7.8 g/cm³ | Stamping+Cutting | >4mm hard | $ | Budget-friendly, simple shapes, large quantities |
| Aluminum | 2.7 g/cm³ | Stamping+Cutting | — | $$ | Lightweight, anodizing, modern look |
| Stainless Steel | — | Stamping | — | $$$ | Maximum corrosion resistance, marine environments |
★ Zinc Alloy — Our Most Popular Material
Why zinc alloy dominates custom medal manufacturing: It melts at just 385°C (725°F), flows exceptionally well into intricate mold cavities, and captures stunning 3D details that stamping simply cannot achieve.
Zinc alloy (commonly Zamak 3, 5, or 7) has a natural white-gray color, excellent corrosion resistance, and takes electroplating beautifully. It's the only material that can achieve true openwork (cut-out) designs and deep relief 3D sculpting.
Our 88-ton die-casting machines inject molten zinc alloy into precision steel molds at high pressure, producing medals with consistent quality at volumes from 100 to 100,000+ pieces.
Zinc Alloy Specs
- Melting point: 385°C (725°F)
- Density: 6.7 g/cm³
- Common grades: Zamak 3, 5, 7
- Min. wall thickness: 2mm
- Best plating adhesion of all materials
- Supports soft enamel, hard enamel, glass enamel, glitter, glow-in-the-dark
- Supports UV printing on 3D surfaces (≤7mm height difference)
- Die-casting cycle: ~15-30 seconds per shot
Surface Treatment Options
Once you've chosen a material, select the surface finish. We offer three main treatment categories:
Electroplating
Electrolytic deposition of a thin metal layer. Best finish quality and widest color range. Available in mirror, matte, antique, and special finishes. 20+ color options including gold, silver, copper, rose gold, chrome, black nickel, and rainbow.
Highest cost
Electrophoresis
Paint particles deposited by electric voltage. Fully coats recessed areas. More affordable than electroplating. Common colors: antique gold, antique silver, antique bronze, antique copper, matte black, gloss black.
Mid-range cost
Spray Painting
High-pressure spray application of epoxy paint. Used when specific colors (white, blue, etc.) cannot be achieved with electroplating or electrophoresis. Matte, non-metallic appearance.
Most economical
Need Help Choosing?
Not sure which material is right for your event? Tell us about your project and we'll recommend the best option.
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