When it comes to custom enamel medals, the choice of metal material plays a crucial role in the final appearance, durability, cost, and production method. The most common metal materials used for custom medals include copper, iron, zinc alloy, and precious metals like gold and silver.
Different metals are suitable for different designs, finishes, and usage scenarios—from premium collectible medals to cost-effective event awards.
Below is a professional overview of the most commonly used metal materials in custom medal manufacturing, along with their characteristics, advantages, and ideal applications.
Copper (Brass, Red Copper, Bronze)
Copper-based materials are the preferred choice for high-end 2D medals. The most commonly used types include red copper and bronze, each serving different production needs.
Key Characteristics of Copper Medals
- Relatively soft metal, easy to strike and engrave
- Excellent surface detail and premium appearance
- Common thickness: 3 mm, 4 mm, 5mm, etc
Red Copper
Red copper is primarily used for hard enamel (cloisonné) medals, which must be fired at extremely high temperatures—up to 850°C. Due to its high melting point and excellent heat resistance, red copper is the only suitable base material for true hard enamel processes.
Bronze
Bronze is widely used for:
- Soft enamel
- Imitation hard enamel
- Baked paint finishes
- Die-struck medals without color filling
Copper is also one of the most frequently used materials for both medals and enamel pins due to its balance of quality, versatility, and aesthetics.
Iron
Iron is one of the most commonly available and cost-effective metals.
Advantages of Iron
- High hardness and strength
- Lower material cost compared to copper
- Electroplated or painted iron medals can closely resemble copper medals in appearance
As a result, iron is often chosen for budget-friendly custom medals where cost control is a priority.
Limitations of Iron
The main drawback of iron medals is their susceptibility to rust, especially during long-distance sea shipping.
For this reason, iron medals are not recommended for overseas customers who require sea freight, unless additional anti-rust treatments are applied.
Zinc Alloy
Zinc alloy is the most widely used material for die-cast medals, particularly for 3D and complex designs. It is considered the best material for casting-based medal production.
Why Zinc Alloy Is Ideal for 3D Medals
Zinc alloy offers several technical advantages:
- Excellent casting performance for complex shapes and thin-walled structures
- Smooth surface finish after casting
- Compatible with electroplating, painting, and coating processes
- Does not absorb iron or stick to molds during die casting
- Strong mechanical properties and good wear resistance at room temperature
- Low melting point (approximately 385°C), making it easy to cast and form
Because of these characteristics, zinc alloy is the go-to material for highly detailed, sculptural, and dimensional medals.
Precious Metals: Gold and Silver
In addition to copper, iron, and zinc alloy, precious metals such as gold and silver are also used for custom medals—primarily for high-end collectible or commemorative pieces.
These materials are most famously seen in international sporting events, such as:
- Olympic gold medals
- Olympic silver medals
Medals made from precious metals carry not only artistic value but also significant symbolic and collectible worth.
Choosing the Right Metal for Your Custom Medal
Each metal material has its own strengths and ideal use cases:
- Copper: Premium quality, fine detail, suitable for enamel and die-struck medals
- Iron: Cost-effective, durable, best for budget-sensitive projects
- Zinc Alloy: Perfect for 3D, complex, and sculptural designs
- Gold & Silver: High-end collectible and ceremonial medals
Selecting the right material ensures your custom medal achieves the best balance of appearance, durability, and budget.
If you are unsure which metal is best for your design, working with an experienced manufacturer can help you make the most informed decision.
Surface Finish vs. Base Material
It is important to note that the surface appearance of a medal does not necessarily indicate its base material.
In custom medal production, the surface is almost always electroplated or finished in a different metal color.
For example, a medal plated in a copper or antique bronze finish is not necessarily made of copper.
Because of electroplating, painting, or coating processes, medals made from iron, zinc alloy, or copper can look very similar on the surface. This makes it difficult—even for experienced buyers—to identify the base metal by appearance alone.
For this reason, the actual material of a custom medal is determined by the manufacturing process and internal structure, not by its surface color or finish.
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