When you need custom medals, one of the first decisions you’ll face is die cast vs die struck medals. Both processes produce metal medals, but their principles, costs, minimum order quantities (MOQs), and ideal applications are very different. Choosing the wrong method can lead to lost design details, budget overruns, or delayed delivery. This guide covers definitions, a detailed comparison table, 3D design recommendations, case examples, and FAQs to help you make the right choice.
1. Definitions and Process Principles
What Is Die Casting?
Die casting involves injecting molten metal (often zinc alloy or aluminum) into a steel mold under high pressure. Once cooled, the metal forms a medal blank. Key characteristics:
- Metal is liquefied and injected into the mold, allowing for complex 3D structures, cutouts, undercuts, and varying thicknesses.
- Mold costs are relatively high, but the unit cost drops quickly as quantity increases.
- Surfaces are usually electroplated (gold, silver, copper, antique bronze, etc.) and color-filled.
Best for: Medals with strong 3D relief, intricate details, or hollow designs.
What Is Die Striking?
Die striking uses a steel die to stamp a metal sheet (often brass, copper, or stainless steel) under high pressure. The metal deforms plastically in its solid state, creating a raised or recessed design. Key characteristics:
- Metal does not melt; pressure forces the design to rise from or sink into the surface.
- Dies last a long time, making this ideal for large-volume production.
- Surfaces can be electroplated, polished, and color-filled. Edges are typically sharper and lines are crisper.
Best for: Flat or low-relief medals, fine lines, clear text, and large batches.
2. Comparison Table: Details, Cost, MOQ, and Applications
| Factor | Die Casting | Die Striking |
|---|---|---|
| Process | Molten metal injected into mold under high pressure | Solid metal sheet stamped under high pressure |
| Detail | Excellent for 3D, cutouts, undercuts, and varied thickness | Crisp lines, ideal for low relief, fine text, and flat designs |
| Mold Cost | Higher (requires a die-casting mold) | Moderate to high (requires a striking die) |
| Unit Cost | Lower with higher quantities; higher for small batches | Very low at high volumes |
| MOQ | Typically lower, suitable for small batches (e.g., 100–500 pcs) | Typically higher, better for large batches (e.g., 1,000+ pcs) |
| Lead Time | Mold + casting + plating + coloring; moderate | Mold + striking + plating + coloring; slightly shorter |
| Weight | Zinc alloy castings are usually heavier and feel substantial | Brass/copper strikes are lighter but can be thicker |
| Applications | 3D medals, irregular shapes, hollow medals, complex badges | Flat medals, fine-text medals, large-volume event medals |
| Surface Finish | Plating, spray paint, enamel, printing | Plating, polishing, enamel, printing |
| Durability | Zinc alloy resists corrosion but may crack if dropped hard | Brass/copper resists corrosion and is tough; less prone to breaking |
Bottom line: For 3D, complex, small-batch medals, choose die casting. For flat, fine-detail, large-batch medals, choose die striking.
3. 3D Designs: Choose Die Casting
If your medal design includes any of the following, die casting is the better choice:
- 3D relief: Raised portraits, animals, buildings, or complex logos.
- Cutouts: Hollow patterns on the edge or internal cutout windows.
- Undercuts or uneven thickness: Features that die striking cannot achieve.
- Irregular outlines: Non-circular, non-standard shapes are easier to cast in one piece.
- Small-batch customization: Die casting usually has a lower MOQ, ideal for events, promotions, or brand commemoratives.
Note: Die casting has higher mold costs. If your design is mostly flat text and you need a very large quantity, die striking may be more economical. But once 3D relief is involved, die casting is often the only option.
4. Case Examples and Applications
Case 1: 3D Marathon Medal
- Design: 3D runner relief + hollow city skyline + dual-tone plating.
- Process: Die casting.
- Why: Cutouts + 3D relief + irregular outline; die striking cannot achieve this.
Case 2: Corporate Annual Commemorative Medal
- Design: Flat raised company logo + fine text + enamel coloring.
- Process: Die striking.
- Why: Flat fine text, 2,000 pieces; die striking offers lower unit cost.
Case 3: Military Badge / Unit Crest
- Design: Complex shield shape + 3D eagle emblem + enamel fill.
- Process: Die casting.
- Why: High 3D detail; enamel filling requires recessed areas.
Case 4: School Sports Day Medal
- Design: Round flat shape + school crest + text + simple border.
- Process: Die striking.
- Why: Simple design, large quantity; die striking is efficient and cost-effective.
If you have a design file, visit Leon Craft Gift for free design advice. We’ll recommend the best process based on your artwork and quantity.
5. FAQ
Q1: Which is more durable, die cast or die struck?
A: Both are durable. Die struck medals are usually brass/copper, which is tough and won’t break easily. Die cast medals are zinc alloy, heavier, but may crack if dropped hard. For normal wear and display, both last for years.
Q2: My design has 3D relief but I only need 200 pieces. Which should I choose?
A: Choose die casting. It has a lower MOQ and can achieve 3D relief. Die striking molds are expensive and not cost-effective for small batches.
Q3: How much do die cast and die struck cost differ?
A: Mold cost: die casting is usually higher than die striking. Unit cost: die striking is lower at high volumes; die casting is more flexible for small batches. Exact pricing depends on design complexity and quantity.
Q4: Can both processes do plating and coloring?
A: Yes. Both can be electroplated in gold, silver, copper, antique bronze, etc., and can use enamel, paint, or printing. The difference is that die casting handles thicker enamel better, while die striking excels at fine line coloring.
Q5: What if I’m not sure which process to choose?
A: Send your artwork and estimated quantity to a factory. A professional engineer will recommend based on detail, quantity, and budget. You can also contact Leon Craft Gift for a free design evaluation.
Q6: Can die striking achieve a 3D look?
A: It can create low relief, but the height is limited. For high relief, cutouts, or undercuts, you must use die casting.
Q7: What are the lead times for each process?
A: Typically 3–7 days for mold making and 7–15 days for production, depending on quantity and finishing. Lead times are similar, but die casting may have more post-processing steps.
Conclusion
Die cast vs die struck medals is not about which is better—it’s about which fits your design, quantity, and budget. Remember three key points:
- For 3D relief, cutouts, irregular shapes, or small batches → choose die casting.
- For flat fine details, crisp text, or large batches → choose die striking.
- Not sure? Let a professional factory evaluate for free.
Free Design: If you’re planning custom medals, visit https://leoncraftgift.com/, upload your artwork, and get free design advice and a quote. Our engineers will help you choose the right process so every medal delivers maximum value.
