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Designing a unique custom medal is about much more than choosing a good-looking shape. For sports events—whether it’s a school competition, a city marathon, or a large international tournament—a well-designed medal should balance visual impact, durability, production feasibility, and budget.
Many event organizers start with a creative idea but run into issues during production: the design is too complex for the chosen material, the size pushes costs too high, or certain colors simply can’t be achieved with the selected process. Understanding how medals are actually made helps you avoid these problems early.
1. Choose the Right Material Based on Your Medal Design
When designing custom sports medals, material selection doesn’t need to be complicated. For most projects, the key is simply understanding which material fits your design and budget.
| Feature | Iron / Brass | Zinc Alloy |
|---|---|---|
| Production method | Stamping | Die casting |
| Shape flexibility | Limited | Very high |
| Typical shapes | Round, square | Any shape |
| 3D / Cut-out / Spinning | ❌ Not suitable | ✅ Fully supported |
| Cost level | Iron: lowest Brass: highest | Medium (higher than iron, lower than brass) |
| Best for | Simple, classic medal designs | Unique, creative, and detailed designs |
When choosing between materials, the decision should always be based on design complexity first, and budget second.
If your medal design is simple, iron is ideal for budget-driven projects, while brass is better suited for high-end events that value material quality over complex shapes; if your goal is to create a unique custom medal with creative forms or special effects, zinc alloy is usually the most practical choice.
2. Medal Size
Medal size plays a major role in both appearance and cost. Choosing the right size depends on the type and scale of your event.
Recommended Medal Sizes for Sports Events
- Small events (school sports days, class competitions): 4–7cm
- Large events (city tournaments, national or international competitions): 6–10cm
For most sports medals, 7cm is an ideal and highly versatile size. At this size, you have enough space to incorporate 3D details, layered elements, or openwork designs without making the medal too heavy or expensive.
Oversized medals—such as 9-10cm—may look impressive at first, but they significantly increase material usage, weight, and production cost. Unless your event specifically requires a statement piece, it’s usually better to focus on design quality rather than size.
3. Production Techniques That Make Custom Medals Stand Out
Unique custom medals rarely rely on a single technique. Most eye-catching designs combine multiple production methods to create depth, contrast, and movement.
3D, Cut-out, and Spinning Designs
- 3D relief adds depth and a premium feel, making logos or mascots stand out.
- Cut-out designs reduce visual heaviness and add sophistication.
- Spinning elements introduce motion and interactivity, often used in modern sports medals.
These techniques increase the unit price because they usually require multiple molds and more complex assembly. As a reference, a single-sided zinc alloy spinning medal (70mm, gold plating) typically costs around USD 7–10 per piece, with a production time of about two weeks. Larger quantities will reduce the unit price.
Enamel vs. UV Printing
Both enamel and UV printing are used to add color to custom medals, but they serve different purposes.
- Enamel coloring offers a classic, durable finish and works well for solid colors.
- UV printing is essential for designs with gradients, shading, or photographic details, which enamel cannot achieve.
In general, enamel is slightly more expensive than UV printing. f you’d like to understand how different special effects impact the final medal cost, you can refer to our detailed Medal Price Guide for a clearer comparison.
4. Medal Accessories
The ribbon is the most important accessory for a medal, and its proportions directly affect the final presentation.
Common Ribbon Widths and Lengths
Common ribbon widths include 10mm, 13mm, 15mm, 20mm, 25mm, 30mm, and 38mm, with 30mm being the most popular choice.
For length, 900–1000mm is standard. This length allows the medal to be worn comfortably from the back of the neck to the chest. For children’s sports events, 900mm is usually sufficient.
A 70mm medal paired with a 30mm ribbon is widely considered a balanced and visually pleasing combination, though proportions can be adjusted based on design preference.
Ribbon Materials and Customization
Common ribbon materials include polyester satin and grosgrain, while large-scale or high-profile events may choose real silk satin for a more premium feel.
Ribbons can be customized with printed event names, years, logos, or slogans, adding another layer of branding and memorability to your sports medals.
Final Thoughts
The most successful custom sports medals are designed with both creativity and production reality in mind. By carefully considering material, size, production techniques, and accessories, you can create a medal that looks unique, feels substantial, and stays within budget.
If you’re unsure which material or process best suits your design, you can share your artwork and budget with our team. We’ll help you refine the design, select the right production methods, and provide a clear, detailed quote—so your custom medals turn out exactly as envisioned.
