Most buyers come to us already comparing “cheap” and “premium,” and they assume the metal is the whole story. It is not — but it is the single decision that locks in weight, finish, detail, and shipping cost before a single mold is cut. Aluminum and zinc alloy are the two materials behind almost every custom aluminum medals and medal alloy search, and they pull in opposite directions: one is the lightest metal we work with, the other is the most detailed. For the full field — including brass, iron, and stainless steel — see our medal materials guide, then come back here for the aluminum-versus-zinc decision in depth.
Why This Comparison Is Harder Than It Looks
Aluminum and zinc alloy are not two grades of the same thing. They are made by two completely different manufacturing routes, and that difference cascades into everything else:
- Zinc alloy is die-cast. Molten metal is injected under pressure into a steel mold, so it can form deep three-dimensional relief, undercuts, and true openwork cut-outs.
- Aluminum is stamped and cut. Flat sheet is pressed between dies and punched to shape, so it produces crisp flat graphics but cannot capture deep 3D relief or complex cut-outs.
So when someone asks us “which is better,” the honest answer is: it depends on what your design actually is. A flat silhouette logo and a sculpted runner figure are not the same job, and the metal that suits one is wrong for the other. This article walks through weight, forming, finish, cost, shipping, and sustainability so you can decide with real numbers instead of marketing copy.
Aluminum: The Lightweight Option
Aluminum sits at 2.7 g/cm³ — roughly 40% of the mass of zinc alloy at 6.7 g/cm³ for the same volume. That single figure explains most of why people choose it.
What Aluminum Is Good At
- Low weight. A medal that hangs on a ribbon for a full marathon or a full day of conference wear is a genuinely different experience at 2.7 g/cm³ versus 6.7 g/cm³.
- Anodizing. Aluminum is the metal that anodizing was designed for. The surface is converted into an oxide layer and dyed, so the color is part of the metal rather than a coating sitting on top.
- Flat, graphic detail. Logos, silhouettes, clean geometric shapes, and thin, even lines reproduce beautifully because the process is stamping from flat sheet.
- Recyclability. Aluminum is one of the most widely recycled metals in the world, with an established scrap stream.
Where Aluminum Falls Short
We will be blunt, because it saves buyers a costly mistake. Aluminum cannot capture deep 3D relief. It cannot do true openwork or intricate cut-outs the way die-cast zinc can. If your design is a raised mascot, a sculpted landmark, or a hollow frame, aluminum is the wrong tool — no stamping press will form it. Anodizing also gives you a matte, flat finish; it will not produce the reflective mirror-gold look that a plated medal delivers. If you want color permanence with a flat graphic, aluminum is excellent. If you want depth, it is not.
Zinc Alloy: The Detail Workhorse
Zinc alloy — specifically the Zamak 3, 5, and 7 grades — is the material most custom medals are actually made from. We die-cast it on an 88-ton press, and the alloy melts at around 385°C, which lets it flow into every crevice of a steel mold.
What Zinc Alloy Is Good At
- Deep 3D relief. Molten zinc captures undercuts and sculpted detail that stamping physically cannot.
- Openwork and cut-outs. Die-casting is the only process among the two that can produce true hollow designs.
- Plating adhesion. Zinc alloy takes electroplating better than any other medal metal we use — mirror gold, antique silver, rainbow, and two-tone finishes all read clearly.
- Full color via enamel. Combined with soft or hard enamel, zinc carries multiple colors inside recessed areas.
Where Zinc Alloy Falls Short
It is heavier, and at 6.7 g/cm³ that weight is real. It costs more per piece than aluminum at low volume because tooling for a steel mold is a bigger upfront investment. And like any plated metal, the finish quality depends entirely on the plating stack underneath — cut corners there and the finish will lift. Our manufacturing process shows exactly where casting and plating sit in the line.
Aluminum vs Zinc Alloy: Head-to-Head
| Attribute | Aluminum | Zinc Alloy |
|---|---|---|
| Density | 2.7 g/cm³ | 6.7 g/cm³ |
| Forming route | Stamping + cutting from sheet | Die-casting on an 88-ton press |
| Minimum thickness | Thin sheet, design-dependent | 2 mm minimum wall thickness |
| Relief capability | Flat / shallow graphic detail | Deep 3D; minimum relief 0.4 mm (we recommend 0.6–0.8 mm) |
| Minimum line width | Design-dependent on die | 0.3 mm |
| Openwork / cut-outs | Not practical | Yes |
| Finish route | Anodizing (dyed oxide, matte) | Electroplating (metallic, reflective) |
| Color | Any dyed color, including brights | Metal tones plus enamel colors |
| Weight feel | Very light | Mid to heavy |
| Relative unit cost | Lower at low volume | Higher tooling, competitive at volume |
| Best use | Finisher medals, flat graphic logos, lightweight events | Podium awards, sculpted detail, openwork, enamel color |
The relief figure is the one buyers most often underestimate. On die-cast zinc, our minimum relief is 0.4 mm, and we strongly recommend 0.6–0.8 mm so the detail reads cleanly after plating and any enamel fill. Push below that and the design turns muddy — the metal simply cannot hold the shape.
Forming Route: Why Stamping and Die-Casting Cannot Swap
This is the technical heart of the comparison, and it is where most purchasing mistakes are born.
Die-casting zinc starts with a steel mold. Molten zinc alloy at roughly 385°C is injected under pressure on an 88-ton press. Because the metal is liquid, it fills three-dimensional cavities, forms undercuts, and flows around a steel core to create openwork. The result is a sculpted object. Minimum wall thickness is 2 mm; go thinner and the metal will not fill reliably.
Stamping aluminum starts with flat sheet. A die presses the sheet into shape and punches the outline. Because the metal stays solid throughout, you get crisp edges and precise flat graphics — but no undercuts, and no deep relief. Aluminum is also worked by cutting, which is how clean flat shapes and thin lines are achieved.
The practical consequence: the forming route is decided by the design, not the budget. If you bring us a design with deep 3D relief and ask for aluminum to save weight, we cannot stamp that relief into sheet. We would either rework the artwork into a flatter graphic that suits aluminum, or make it in die-cast zinc and manage the weight another way — for example by adjusting the diameter rather than the thickness. Sending us your artwork early is the cheapest way to avoid this dead end.
Finish: Anodizing vs Plating
The two metals take fundamentally different finishes, and this matters as much as the metal itself.
Anodizing applies to aluminum. The surface is grown into an oxide layer and dyed, so there is no separate coating to chip. It is stable and matte, and it handles bright, non-metallic colors well. It is also why anodized medals tend to look modern and understated. If color permanence on a flat surface is your priority, this is a strong route — we cover it in detail in our anodized vs regular medals article.
Plating applies to zinc alloy. It deposits a separate metal layer on top, which is why the base adhesion layer matters enormously. Our line runs nine plating steps, beginning with an alkaline copper base of about 500 seconds, followed by acid copper for 20 to 60 minutes, before any color goes on. The plated piece is then dried in a tunnel oven at 100°C for 40 minutes to fix the finish and lacquer. That base copper layer is what stops the finish lifting or discoloring. Cutting the plating stages is the most common reason a “cheap” zinc medal looks tired within a year — which is why we do not offer a shortened plating option.
If you want the reflective, traditional, metallic look, plating on zinc is the route. If you want a durable matte color that cannot chip, anodizing on aluminum is the route. You cannot get both from one metal.
Weight and Shipping Economics
Weight is where aluminum’s low density turns into money.
At 2.7 g/cm³, aluminum is about 40% of zinc’s mass for the same volume. On a single medal that is a feel difference. On a 5,000-piece order shipped internationally, it is a freight difference — lighter medals mean lower dimensional and actual weight, which can reduce air freight cost meaningfully on large events. For races where finishers may receive tens of thousands of medals, that adds up fast, and it is a real reason event organizers reach for lightweight medals. If your priority is a race or mass-participation event, our race medals range is built around exactly this trade-off.
The counter-argument is perceived value. A podium award is supposed to feel substantial in the hand, and weight is part of how recipients judge it. A very light medal can read as cheap even when the design is excellent. For championship and commemorative pieces, heavier usually wins — which is why most podium medals we produce are die-cast zinc, not aluminum.
Cost: Where Each Wins
Cost comparisons depend heavily on volume, because the two routes front-load their costs differently.
| Factor | Aluminum (stamped) | Zinc Alloy (die-cast) |
|---|---|---|
| Tooling | Lower — simpler dies | Higher — steel mold per design |
| Unit cost at low volume | Lower | Higher, tooling dominates |
| Unit cost at high volume | Low | Low, tooling amortizes |
| MOQ at our factory | 100 pcs per design | 100 pcs per design |
| Weight-based freight | Lower | Higher |
For a small, one-off run with flat artwork, aluminum usually wins on price. For a recurring event where tooling amortizes across years, die-cast zinc closes the gap and delivers more perceived value per piece. If you are ordering a recurring event medal, ask whether your tooling can be held on file — we retain molds for reorders, which removes tooling cost from year two onward. Our bulk custom medals page explains how quantity steps affect per-piece pricing.
One more honest note on cost: aluminum and zinc supply conditions move independently, so unit prices can shift between quotes. We confirm material pricing at the time of quoting rather than promising a fixed number months ahead.
Designing for Each Metal: Practical Rules
Because the two metals are made so differently, the artwork rules differ too. These are the guidelines our design team applies every day.
For aluminum (stamped):
- Keep the design flat. Think in silhouettes, not sculptures.
- Use clean, even line weights. Very fine detail is limited by the die, so avoid hair-thin elements.
- Avoid undercuts, hollow frames, and layered depth — none of these are stampable.
- Design for color blocks, since anodizing dyes flat areas rather than filling recessed ones.
- If you want a metallic edge, that comes from the base metal or a separate trim, not from plating.
For zinc alloy (die-cast):
- You have real depth. Minimum relief is 0.4 mm, and we recommend 0.6–0.8 mm so detail survives plating.
- Minimum line width is 0.3 mm. Below that, lines blur together in the mold.
- Minimum wall thickness is 2 mm. Thinner walls will not fill reliably under casting pressure.
- Openwork and cut-outs are possible — this is the only one of the two metals that can do them.
- Plan your enamel colors early. Soft enamel fills recessed areas at a 0.3 mm minimum width; hard/glass enamel needs at least 0.5 mm; and UV printing can cover relief up to 7 mm for photographic color.
The single most useful habit is to send us your design before you commit to a metal. A five-minute review tells you whether the artwork is even manufacturable in the metal you have in mind — which is far cheaper than discovering it after tooling.
Ribbons, Packaging, and Presentation
Weight and metal choice also shape how a medal is presented, and presentation is part of what recipients remember.
Standard ribbons run 860–900 mm long and 20–30 mm wide, with a shorter 800 × 20 mm ribbon for kids’ events. Lighter aluminum medals hang differently on a ribbon than heavier zinc ones — a very light medal can swing more on a long ribbon, so attachment type matters. We match the ribbon and attachment to the metal so the medal sits correctly rather than twisting.
Packaging is the same story. We offer PP bags, OPP bags, zip bags, velvet bags, paper cards, paper boxes, velvet boxes, acrylic boxes, and blister packs. A heavier die-cast podium medal usually deserves a velvet or paper box that reflects its value, while a high-volume aluminum finisher medal is often packed more simply on a paper card. If you are ordering at volume, packaging choice has a real effect on per-piece cost and shipping weight, so decide it alongside the metal rather than after.
Eco and Recyclability: What We Can and Cannot Claim
Aluminum’s recyclability is genuine — it is one of the most established recycling streams in metals, and recycled aluminum uses far less energy than primary production. That makes aluminum a reasonable choice for buyers with sustainability goals, and anodizing adds no separate coating that complicates the material stream.
But we will not overstate it. We cannot certify recycled-content percentage per lot. The aluminum we buy is not always traceable to a specific recycled share, and we will not put a number on a certificate we cannot verify. And to be completely clear: no product we make is “carbon neutral” or “zero emissions.” Any manufacturer claiming that for a die-cast or stamped metal medal is stretching the truth. What we can say honestly is that aluminum is lighter — and lighter means less freight — and that both aluminum and zinc are recyclable at end of life. For the broader picture of sustainable options and their limits, see our eco-friendly custom medals guide.
When Aluminum Wins
Choose aluminum when:
- Your design is flat and graphic — logos, silhouettes, clean geometry, thin even lines.
- Weight matters — long-distance finisher medals, large-participation events, or any award worn for hours.
- You want durable matte color that cannot chip, via anodizing.
- Freight cost is a real line item and you are shipping thousands of pieces.
- Sustainability is a stated goal and recyclability is part of your story.
When Zinc Alloy Wins
Choose zinc alloy when:
- Your design has deep 3D relief — a mascot, a sculpted landmark, a raised crest.
- You need openwork or cut-out shapes, which only die-casting can produce.
- You want a reflective metallic finish — mirror gold, antique silver, two-tone, rainbow.
- You want enamel color combined with relief. Soft enamel fills recessed areas at a minimum of 0.3 mm width; hard/glass enamel needs at least 0.5 mm; and UV printing can cover relief up to 7 mm.
- The award is a podium or commemorative piece where weight signals value.
Frequently Asked Questions
Is aluminum lighter than zinc alloy for medals?
Yes, substantially. Aluminum is 2.7 g/cm³ and zinc alloy is 6.7 g/cm³, so for the same volume aluminum is about 40% of the mass. That difference is noticeable in the hand and becomes a real freight saving on large orders, which is why long-distance finisher medals often use aluminum while podium awards usually use zinc.
Can aluminum medals have 3D relief?
No — not meaningfully. Aluminum is stamped and cut from flat sheet, so it produces crisp flat graphics but cannot form deep 3D relief, undercuts, or openwork. Deep relief requires die-casting, where molten zinc alloy at around 385°C flows into a steel mold on an 88-ton press. If your design depends on depth, it must be die-cast.
Which metal is cheaper, aluminum or zinc alloy?
It depends on volume. For a small run with flat artwork, stamped aluminum is usually cheaper because the dies are simpler and tooling is lower. For a recurring event where a steel mold amortizes across years, die-cast zinc becomes competitive and gives a more premium feel. Both carry a 100-piece minimum per design at our factory.
Do aluminum medals use anodizing instead of plating?
Generally yes. Anodizing converts the aluminum surface into an oxide layer and dyes it, so the color is part of the metal and cannot chip. Plating deposits a separate metal layer and is used on zinc alloy. Anodizing gives a durable matte finish; plating gives a reflective metallic look. You cannot get both from one metal.
Are aluminum medals more eco-friendly?
Partly, and we are careful about the claim. Aluminum is highly recyclable and lighter, which lowers shipping emissions — genuine advantages. But we cannot certify recycled-content percentage per lot, and no medal we make is “carbon neutral” or “zero emissions.” Treat recyclability and reduced freight as the real, verifiable benefits.
Can I get both deep relief and light weight?
Only by changing the design. You cannot stamp deep relief into aluminum. The workaround is to make the medal in die-cast zinc for the detail and manage weight through a smaller diameter or thinner wall — never below the 2 mm minimum — rather than by switching to aluminum. Send us the artwork and we will tell you which lever actually works.
Get a Quote for Aluminum or Zinc Medals
If you are weighing aluminum against zinc for a specific design, the fastest way to settle it is to send us the artwork. Our design team will produce a free design proof within 24 hours, with unlimited revisions, and tell you honestly which metal your design can actually be made in — including when that means telling you aluminum will not hold the relief you have in mind.
Our factory, Badge Artisans, has been producing metal medals and trophies since 2010, with a capacity of 30,000+ pieces per day, an MOQ of just 100 pcs per design, bulk lead times of 7–15 days, and samples in 7–10 days. We run three-stage QC with 100% conforming delivery and export to 50+ countries. Certifications include BSCI, Disney, ISO9001, Reach, RoHS, TUV Rheinland, Sedex, and USJ.
Tell us your event, quantity, and target look, and we will come back with a material recommendation and a quote. Browse our full custom medals range or contact us directly to start your project. Payment terms are T/T 30% deposit and 70% balance.
Related product page: medals with a rotating centre — our spinning medal range: a moving inner disc on a die-cast body, 100-piece minimum.
