A Guide to the Top 10 Manufacturing Processes for Custom Metal Medals

When creating custom metal medals, a variety of manufacturing processes can be used to achieve the desired look, feel, and level of detail. Each technique has its own unique characteristics, applications, and advantages. Understanding these options is crucial for selecting the best method for your specific project. Below, we summarize ten of the most common processes in the industry.

1. Transfer Medals: This method involves prefabricating graphics and text on transfer paper, which is then applied to the workpiece. It allows for very clear and precise graphics, making it ideal for detailed designs, though production costs can be higher.
2. Silk-Printed Medals: A versatile and widely adaptable technique used on metal, plastic, and acrylic surfaces. Silk-printing is known for its cost-effectiveness and broad application, especially for mechanical panels and similar items.
3. Pad Printing Medals: Perfect for uneven or curved surfaces, this process uses a silicone head to pick up ink from an etched plate and transfer it to the workpiece.
4. Offset Printing Medals: In this circular flattening method, graphics are transferred from a rubber roller to a flat workpiece. It produces fine, detailed images and is commonly used for items like watch faces.
5. Electroforming Medals: Using a high current density, metal is deposited onto a 'master mold' and then peeled off. This process is used to create ultra-thin, self-adhesive nameplates and has become very popular in recent years.
6. Electroplating Medals: Suitable for both metal and plastic, this process involves depositing ionic metals like chromium, nickel, or gold onto an etched surface. The result is a bright, noble-looking finish with excellent corrosion resistance.
7. Electrophoresis Medals: Often used with etching, this technique uses a direct current electric field to deposit polarized paint onto the surface of bare metal, creating a durable and even coating.
8. Highlighting Medals: This process creates a high-gloss effect by turning the convex surface of pressed aluminum with a diamond knife. It is a relatively economical and affordable way to produce a striking nameplate.
9. PVC Soft Plastic Medals: Made from a polycarbonate base (PC or PVC), these decorative medals are created through thermal injection molding and finished with coloring or vacuum plating. They offer good abrasion and corrosion resistance, making them popular for appliances and machinery.
10. Crystal Drop Plastic Medals: A finishing process where transparent polyurethane is applied to the medal's surface for decoration and protection. This creates a slightly convex, smooth, and bright finish, widely used in electronics and home appliances.