Ordering custom metal medals, challenge coins and lapel pins is a six-step process: choose the relief level, choose the material, choose the finish, set the size, specify the edge treatment, and select the packaging. Each step has a fixed set of options, and each one changes both the unit cost and the minimum order quantity. The artwork needs to arrive as clean vector files with the text already converted to outlines. Medal and badge tooling is simpler than sculpted souvenir work, so more designs reach the 500-piece tier â our 500-piece minimum guide lists the badge products available at that quantity.
Step 1: Choose the Relief Level
The relief level is the single most consequential decision on a medal, because it determines the visual impact, the perceived value, the tooling cost and the finishing steps. Relief is the depth of the modelling on the face of the piece, and there are three levels used for medals, coins and badges.
| Relief level | What it looks like | Tooling implication | Cost position | MOQ tier |
|---|---|---|---|---|
| 2D (flat) | The design is cut into the surface as a flat stamped form | Press tool or shallow die; fastest and cheapest tooling | Lowest | 100 â 500 pcs |
| 2.5D (half relief) | The design stands proud of the surface but stays below full depth | Die-cast with a shallower cavity; a middle path | Middle | 500 â 1,000 pcs |
| 3D (full relief) | The design is fully modelled and stands clear of the rim | Full die-cast with a deep cavity; the most demanding tool | Highest | 500 â 1,000 pcs |
A practical note on 2D. A flat stamped medal with a printed or enamel-filled surface is not a cheaper version of a 3D medal, it is a different product. It reads as a token rather than a commemorative piece, and it does not carry the same value when presented as an award. If the medal is going to be worn or displayed rather than handed out, 2.5D is usually the sensible starting point.
Step 2: Choose the Material
The material choice drives weight, perceived value and the available finishes. These are the four options used across our medal, coin and pin range.
| Material | Appearance | Weight feel | Best suited to | MOQ tier |
|---|---|---|---|---|
| Zinc alloy | Silver base, fully finishable in any plating colour | Medium to heavy | General-purpose medals, coins and club badges | 500 â 1,000 pcs |
| Brass | Warmer yellow base, deepens with antique finishes | Heavy | Premium coins, service medals, recognition awards | 500 â 1,000 pcs |
| Iron | Dark base, takes enamel or printed colour well | Light | Flat 2D forms and stamp-style medals | 100 â 500 pcs |
| Bronze and stainless steel | Copper-brown or bright steel base | Heavy or bright depending on the alloy | Collectors coins, premium lapel pins | 500 â 1,000 pcs |
| Stainless steel with butterfly clutch | Bright steel pin back on a flat pin | Light | Lapel pins, school and academic badges | 500 â 1,000 pcs |
Step 3: Choose the Finish
Finish is what makes a medal look issued rather than manufactured. The finishes available across our medal and coin range are listed below with the effect each one has.
| Finish | Effect | Typical use | Note for orderers |
|---|---|---|---|
| Gold | Bright warm metallic | First-place awards, premium recognition | Most requested finish |
| Silver | Bright cool metallic | Second-place awards, general recognition | Pairs with the coin edge detail |
| Antique gold | Darkened recesses, worn highlight | Heritage and civic designs | Shows relief depth strongly |
| Antique silver | Darkened recesses, worn highlight | Military, service and heritage designs | Shows relief depth strongly |
| Antique bronze | Brown aged tone | Fire, rescue and service organisations | Matches the service tradition |
| Black nickel | Dark satin metallic | Modern, design-led and brand programmes | Pairs well with enamel colour |
| Dual tone | Two plating colours, one polished one matte | Premium coins and award programmes | Requires a two-stage plating specification |
Step 4: Set the Size and Diameter
Medal size is quoted by diameter, and the size is tied to how it is used. A medal meant to be worn on a lanyard is a different size from one meant to be held or displayed.
| Diameter band | Typical use | Metal weight | Logo and text capacity | MOQ tier |
|---|---|---|---|---|
| Under 30 mm | Badge-style token, add-on, event handout | 5 â 15 g | Single letter or a small icon only | 100 â 500 pcs |
| 30 â 45 mm | Standard lapel pin and club badge | 15 â 35 g | Compact logo with one line of text | 500 â 1,000 pcs |
| 45 â 60 mm | Standard challenge coin and recognition medal | 35 â 80 g | Logo, artwork and two or three text lines | 500 â 1,000 pcs |
| 60 â 80 mm | Presentation medal and collectors coin | 80 â 150 g | Full artwork, ring text and a detailed reverse | 500 â 1,000 pcs |
| Over 80 mm | Display piece, commemorative plate | 150 g and above | Full artwork with generous negative space | 1,000 pcs |
Step 5: Specify the Edge and Backing
The edge treatment and the pin backing are small decisions that change the finished product noticeably. Both are specified at the artwork stage rather than at the finishing stage.
| Specification | Options | Effect on appearance | Effect on cost and lead time |
|---|---|---|---|
| Edge treatment | Standard plain edge | Clean and functional, the default on most medals | Included, no impact on lead time |
| Edge treatment | Rope edge or reed edge | A visible textured rim, often used on coin-shaped awards | Adds a finishing step |
| Edge treatment | Rounded or raised lip | Protects the face and frames the relief | Requires a modified die |
| Pin backing | Butterfly clutch | The standard pin hardware, easy to attach and remove | Standard; included on lapel pins |
| Pin backing | Rubber clutch or safety pin | Safer on clothing, suits school and academy badges | Low additional cost |
| Pin backing | Screw or rivet fixing | Permanent fixing for a badge meant to be displayed | Adds an assembly step |
| Attachment | Jump ring, split ring or chain | Connects the medal to a lanyard, badge reel or keyring | Standard hardware, minor cost |
Step 6: Select the Packaging
Medals are usually handed over in a presentation format, so packaging is a real part of the specification rather than an afterthought.
| Packaging | Format | Best for | Cost position |
|---|---|---|---|
| Polybag | Protective bag, one per piece | Bulk distribution, volunteer event hand-out | Lowest |
| PVC pouch | Clear soft pouch | Lighter pins and badges presented cleanly | Low |
| Backing card | Printed card with a hanging hole | Retail peg display for pins and small badges | Medium |
| Individual box | Separate box per piece | Award programme where the presentation matters | Medium to high |
| Gift box | Presentation box for one piece or a set | Premium recognition and corporate programme | Medium to high |
| Display box | Counter or shelf box holding multiple pieces | Retail and exhibition counter display | Medium |
Artwork Requirements
Artwork causes more delay than tooling does. The requirements below are what allow a sample to be produced without a second round of revision.
- Vector files only. AI, EPS, SVG or high-resolution PDF. A raster image at 300 dpi is acceptable for a flat 2D design but not for a 3D relief.
- Text converted to outlines before sending, so the factory is not substituting fonts.
- Front and back artwork as separate files, each clearly named. A coin with different artwork on each face needs both.
- A note of the text exactly as it must be read, including the spelling of names, dates and organisation titles. This is checked against the approved sample before mass production.
- Indicate the finish colours and the enamel colours if any colour fill is required.
- State the diameter and the thickness, or the size of the image area if the size is open.
- Flag any symbol, crest or organisation emblem that has a required colour or form, because these are usually the parts that need a specific plating instruction.
Lead Time and Minimum Quantities
Two parameters are fixed for every medal order, whatever the specification.
- Sample: about 7 days for a pre-production sample.
- Production: about 15-20 days for mass production after the sample is approved. Tooling for a new shape is scheduled before the sample stage.
- Minimum order quantity: around 100 pieces for flat 2D stock-form designs, around 500 pieces for standard designs using existing tooling, and around 1,000 pieces for most fully custom 3D shapes. The minimum applies per design, so a set of four medal faces at 1,000 pieces each is a 4,000-piece order.
- Shipping: available by express, by air and by sea.
A Worked Example: A Club Recognition Set
This shows how the six steps combine into a real specification, so you can see the reasoning rather than only the options.
| Requirement | Decision | Reason |
|---|---|---|
| Awarded to a junior club | 45 mm diameter | Worn on a lanyard and handed out at a club event, so the small badge format fits |
| Must read as a formal award | 2.5D relief in zinc alloy with antique gold finish | Half relief gives visible depth at a lower tooling cost than full 3D, and antique gold shows the relief detail |
| Carries the club emblem and the year | Front: emblem in relief, reverse: year and member name | Two faces need two artwork files, both outlined and both checked against the sample |
| Given out in a ceremony | Individual box with a printed insert | The presentation is part of the recognition moment for a junior member |
| One design, three sizes | Single design at 45 mm, minimum 500 pcs | One design keeps the tooling count at one and the order in the 500 piece tier |
Medals Against Other Metal Gift Formats
A medal carries a different message from a giveaway, and choosing the wrong format for the situation wastes a production run. Custom metal gifts for trade shows compares the medal against keychains, bottle openers, pins and charms where the piece is handed over to a visitor rather than awarded to a person. Custom metal bag charms covers the smaller ornament formats used where a medal would be too heavy for the context. For gifting programmes where the metal piece accompanies a bottle rather than being the award itself, custom wine accessories sets out the alternatives, and custom Christmas metal gifts covers the seasonal recognition and gifting formats.
Related Pages
Our current custom medals and badges range shows the challenge coins, lapel pins and enamel badge formats available, including the Masonic and fraternal lapel pin families, the recognition challenge coins and the fire rescue coin. For the general production workflow that applies to medals as well as other metal gifts, see the 12-point manufacturer checklist and quality control before shipment. Timing, cost and packing are covered in lead time and shipping, the pricing guide and packaging options.
Frequently Asked Questions
What is the difference between a custom medal and a challenge coin?
A medal is a general term and can be any shape, while a challenge coin is a specific format: a round coin-shaped piece with a defined rim, usually with different artwork on the front and the back, and normally with an edge treatment. In practice a challenge coin is a medal with the round coin format. Both use the same manufacturing route, so the decision is about shape and presentation rather than a different process.
How much does a custom metal medal cost?
We do not publish unit prices because a medal quote depends on diameter, relief level, material, finish count and the edge treatment. What we can state precisely is the quantity structure: at around 100 pieces you are paying the highest unit cost because tooling is not amortised, at 500 pieces the standard tooling becomes practical, and at 1,000 pieces and above a fully custom 3D shape reaches its lowest unit cost. A flat 2D stamped design sits at the bottom of the range, a 2.5D zinc alloy design in the middle, and a 3D design in brass or bronze at the top.
What is the minimum order quantity for custom medals?
In our catalogue minimums fall into three tiers: around 100 pieces for flat 2D stock-form designs where no new mould is opened, around 500 pieces for standard designs using existing tooling, and around 1,000 pieces for most fully custom 3D shapes. The minimum applies per design, so a four-face medal set at 1,000 pieces each is a 4,000-piece order. For lapel pins and badges the practical tier is usually 500 pieces.
How long does it take to make custom medals?
Allow about 7 days for a pre-production sample and about 15-20 days for mass production after the sample is approved. Tooling for a new shape is scheduled before the sample stage. Shipping is available by express, by air and by sea. For a dated event, work backwards from the event date and add the transit time to the production schedule rather than to the sample date.
Can I get different artwork on the front and back of a medal?
Yes, this is standard and it is how challenge coins are usually produced. Send the front and back as two separate artwork files with the text converted to outlines, and state clearly which side each file is for. A design with a different image on each face needs the relief depth checked separately on both, because one side may end up shallower than the other if they are modelled at different depths.
What is 2.5D relief and should I choose it?
2.5D means the design stands proud of the surface but stays below full depth, with the background sunk slightly. It is the middle path between a flat 2D stamp and a fully modelled 3D piece. It is usually the right choice for a recognition medal because it gives visible depth and shadow, which is what makes a medal look like an award, at a lower tooling cost than full 3D. A flat 2D design reads as a token rather than a commemorative piece.
Do you make lapel pins with a butterfly clutch?
Yes. A butterfly clutch is the standard pin hardware on our lapel pins, and it is easy for the wearer to attach and remove. For school, academy or youth badges a rubber clutch or a safety pin is safer on clothing, and for a badge meant to stay on a display a screw or rivet fixing is used. The pin backing is specified at the artwork stage alongside the edge treatment.
Can you produce enamel badges as well as medals?
Yes. Enamel badges are a flat 2D or 2.5D form with colour poured into recessed areas and cured, then cleaned. They are a lower-cost format than a relief medal and suit school, academic and club identity programmes where a clear, colourful logo carries more weight than modelling. Our current range includes enamel lapel pins, fraternal lodge logo badges, school badges and city landmark enamel pins.
What artwork format do you need for a custom medal?
Vector files: AI, EPS, SVG or a high-resolution PDF. A 300 dpi raster image is acceptable for a flat 2D design but cannot be used for a 3D relief. Text must be converted to outlines before sending, and front and back artwork should be sent as separate named files. State the exact spelling of names, dates and organisation titles in a separate note, because that text is checked against the approved sample before mass production.
Can medals be ordered in a set of different designs?
Yes. A set is treated as separate designs, each with its own artwork file, its own tooling and its own minimum order tier. This is why design count is the main cost driver in a medal programme. Four medal faces at 1,000 pieces each is a 4,000-piece order, while the same four faces at 500 pieces each is a 2,000-piece order across four tools. Adding a design to an existing programme is often the cheapest way to raise the order value without new tooling.
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