Why Material Choice Matters
The material you choose for your custom medals affects everything: how detailed the design can be, how the medal feels in hand, how long it lasts, and how much it costs. At MedalOrigin, we work with five metals, but zinc alloy and brass are the two most popular choices for premium medals.
Zinc Alloy: The Versatile Workhorse
Zinc alloy (specifically Zamak 3, 5, or 7) is our most popular material, and for good reason.
Key Properties
- Density: 6.7 g/cm³ — substantial without being heavy
- Melting point: 385°C (725°F) — flows beautifully into molds
- Process: Die-casting — injected under high pressure into steel molds
- Minimum thickness: 2mm
Advantages
- Best 3D detail: Molten zinc alloy at 385°C flows into every crevice of the mold, capturing intricate 3D details that stamping cannot achieve.
- Openwork (cut-out) designs: Zinc alloy die-casting is the only process that can create true hollow/openwork medal designs.
- Excellent plating adhesion: Zinc alloy takes electroplating better than any other medal material. Mirror gold, antique silver, rainbow plating — all look stunning on zinc alloy.
- Cost-effective: Lower material cost than brass, and the die-casting process is highly efficient at scale (30,000+ pieces per day).
Best For
- Medals with complex 3D relief (runners, buildings, logos)
- Openwork/cut-out designs
- Events needing 100-50,000+ medals
- Any design requiring multiple enamel colors
Brass: Premium Weight & Tradition
Brass has a long history in military medals, challenge coins, and commemorative awards.
Key Properties
- Density: 8.9 g/cm³ — noticeably heavier than zinc alloy
- Natural color: Warm gold-like tone
- Process: Stamping + cutting from brass sheet
- Minimum thickness: 3mm (hard to stamp thicker)
Advantages
- Premium heft: At 8.9 g/cm³, a brass medal feels substantially heavier and more “valuable” in hand.
- Fewer pores: Higher density means fewer internal air pockets — polished surfaces look flawless.
- Traditional appeal: Military units and government agencies often prefer or require brass for tradition and perceived value.
- Natural color: The warm yellow tone means minor scratches are less visible than on plated zinc alloy.
Limitations
- Higher cost: Brass is 20-40% more expensive than zinc alloy.
- Limited 3D detail: Stamping cannot achieve the deep relief and undercuts possible with die-casting.
- Thickness constraints: Brass thicker than 3mm is difficult to stamp precisely.
Head-to-Head Comparison
| Feature | Zinc Alloy | Brass |
|---|---|---|
| 3D Detail | Excellent (die-cast) | Good (stamped) |
| Weight | Medium (6.7 g/cm³) | Heavy (8.9 g/cm³) |
| Cost | $$ | $$$ |
| Openwork | Yes | No |
| Plating | Excellent | Good |
| Best for | Complex designs, large orders | Traditional awards, challenge coins |
Which Should You Choose?
Choose zinc alloy if: You want the most design flexibility, intricate 3D details, openwork designs, or are ordering at volume. This is the right choice for 90% of custom medal projects.
Choose brass if: You need the premium weight and traditional feel, are producing military or government awards, or are making challenge coins where the weight is part of the perceived value.
Still Not Sure?
Our design team can recommend the best material based on your specific design, budget, and event. Contact us for a free consultation — we will create a design in both materials so you can compare.