Our case studies also highlight special projects to show you our manufacturing process.

Medal Design / Virtual Proofing

At the start of the project, we ask clients to send us artwork to include in the medal design. This can be anything from race logo, sponsor logo, sketches, inspirations, past medals, other merch designs. We take anything that you can provide to us and try to gather some ideas. Our artists then work on some rough designs; medal design can take a few days to weeks depending on the complexity of project and rounds of revision. Once the client has approved the final virtual proof, the artwork is sent to the production department. 

Clients collaboration: we will send rough drafts and revisions to clients during this phase to make sure our designs are done in the right direction. It is the best time for verify copy, dates, colors and all logo versions are accurate. Making changes at this point is quite painless; it is a matter of our graphic designers revising the artwork. Clients responding in a timely manner will help the project along to the next phase.

Timeline: a few days to a few weeks, depending on the number of revisions and how quickly clients respond. Any text/color/logo change after this phase, no matter how small, will delay the project.

Molding

Once the virtual mockup is approved, We start with zinc alloy, using the customer’s artwork to make a mold. It is similar to how a rubber stamp inks designs on paper. We are making the stamps that will be used for producing the medals later on. Our skilled craftsmen actually hand sculpt the fine details to make sure it matches the digital artwork. 

Timeline: one to two weeks

 

Sample Making / Approval

Since race medals are custom products from start to finish, we want to make sure they are done to the clients specifications. Sometimes a medal viewed on virtual mockup can be drastically different from the computer screen to actual medal. Rather than making all of the medals, we first make a few samples. We go through the exact same steps (which we will outline below) of producing tens of thousands of medals, instead we just make a few. Our overseas production team takes pictures of the medal for clients to approve. It is an option to ship sample medals but it will take an extra week. 

Clients Collaborations: Clients have a chance to get the first look of their project! Timely approvals will ensure the process will move right along. Delay in approvals will push the project back. 

Timeline: one to two weeks. If changes are required it will take anywhere from a few days to 2 weeks to update the medal, depending on whether we can make the change directly on the mold or a new mold is required.

 

Stamping / Polishing / Electroplating

After samples are approved, we are off to produce all the medals. Using the mold, medals are stamped, this process is mostly done by machine. Here is how ‘virgin’ medals look without any coating or coloring. They still need a lot of work! Virgin medals do not have the polished, smooth surface that we normally see. Medals are polished by hand, one by one. This particular process is labor intensive and can take some time.

Electroplating is the process that coats the virgin medals the color on the metal. Our medal plating chart shows the most popular finishes but we can always customize the metal coating to any specific Pantone color. 

Timeline: two to three weeks. Any changes to the medal design at this point will cause delays and incur significant costs as we have to go a few steps back to fixing or re-creating the mold, samples. 

Coloring

Here is where the magic happens! The marvelous medals are color filled in meticulously one by one, by hand or by machine. Our new UV printing allows for full color printing capabilities and extra shiny raised letters on medals.

Timeline: one to two weeks

 

Race Ribbons / Neckbands

Race ribbons are normally produced at the same time as the medals. Sample ribbons are printed and we will send photos to clients for approval. Check out all about our ribbon printing and ribbon attachments options. Normally race ribbons are 38mm / 1.5″ wide. 

Client Collaboration: similar to the medal samples, ribbons samples are to be approved by clients before mass production. Timely approvals are highly recommended.

Timeline: one to two weeks (concurrent to medals production)

Assembly / Packaging / Shipping

Here at the final stretch of the medal production process we will attach the approved neckbands to the finished medals, polybag each medal, package and ship. We offer different shipping methods based on deadlines: ocean shipping and air shipping. If race date is a couple months away, we can bring down shipping costs significantly by shipping ocean freight. Some clients will order the entire year worth of medals in the beginning of the year for maximum savings. Running out of time? We can air ship the medals either by Fedex or DHL and they can be delivered as quickly as a few days.

Client Collaboration: We can help bring down the cost of medal production if we know the race schedule for the year ahead of time. Our experience in the race medal business for over 10 years has taught us a few tricks on how to improve race directors’ bottom line. 

Timeline: up to one week