Medal Die

A Medal Die is a precision tool used in the manufacturing of medals. It is typically made from hardened steel and contains an engraved design that will be stamped or pressed onto metal blanks to create a finished medal. The die may include detailed images, text, logos, or patterns that are transferred to the surface of the medal during the striking or embossing process.

1.1, A metal die used for stamping or die-casting medal designs

Historical Origins

• Ancient Civilizations:
  The use of dies for creating metal designs dates back thousands of years. In Ancient Greece and Rome, artisans used engraved dies to strike coins and military medallions. These dies were often hand-carved and made from hardened bronze or iron. The designs conveyed authority, mythology, or notable achievements.

• Medieval Period:
  During the Middle Ages, dies were used to produce religious medallions and royal insignias. Engravers carved the dies by hand, and hammer-struck techniques were common. The medal die became a medium for storytelling and honoring figures of power or faith.

• Renaissance & Early Modern Period (15th–18th century):
  The rise of artistic expression brought about highly detailed medal dies used for portraits, awards, and commemorative events. Dies were often the work of master engravers and reflected the artistic trends of the era.

Industrial Age & Mass Production

• 19th Century Onward:
  The invention of screw presses and later hydraulic presses revolutionized medal production. Medal dies were now manufactured using steel, enabling repeated use for thousands of impressions. This era saw mass production of military decorations, school awards, and state honors.

• Die-Making Process Improvement:
  By the late 19th and 20th centuries, new techniques like pantograph engraving and photochemical etching allowed for more intricate and standardized designs. The medal die industry expanded significantly, especially during wartime, when demand for medals surged.

Modern Medal Die Production

• Materials & Technology:
  Today, medal dies are made from hardened tool steel using CNC machines, laser engraving, or electrical discharge machining (EDM). These methods offer high precision and consistency, allowing intricate 3D designs and fine lettering.

• Applications:
  Modern medal dies are used in various industries:

  • Sports & Education: for awards, trophies, and badges

  • Military & Government: for service medals and official honors

  • Commemorative Items: for events, exhibitions, or national celebrations

  • Corporate Branding: custom metal tokens, keychains, and promotional medals

• Types of Dies:

  • Obverse and reverse dies: for front and back design

  • Single or split dies: depending on whether one or both sides are struck

  • Custom 3D dies: for multi-dimensional effects

Why Medal Dies Matter Today

• Medal dies are more than tools—they are symbols of honor, achievement, and history. The transition from ancient handcraft to digital precision reflects not only technological progress but also humanity’s lasting desire to celebrate excellence and preserve memory through metal.

1.2, Stamping dies, engraving dies, electro-erosion dies, CNC precision engraving dies

 1. Stamping Dies 

Definition:
Stamping dies are metal tools used to imprint a design onto a blank medal piece by applying high pressure, typically using a hydraulic or mechanical press.

Historical Use:
Stamping has ancient roots — coin and medal stamping began as early as ancient Greece and Rome using hand hammers and engraved dies. Over time, with the development of mechanical presses during the Industrial Revolution, mass production of medals became possible.

Modern Use:
Today, stamping dies are commonly used for producing medals in large quantities. The process is fast and cost-efficient, suitable for military medals, commemorative coins, and sports medals.

Advantages:

• Durable and reusable

• High-speed production

• Uniform results

 2. Engraving Dies 

Definition:
Engraving dies are manually or mechanically carved blocks of hardened steel with intricate designs. These dies are pressed into softer metal to create raised or recessed patterns.

Historical Use:
Traditionally, all dies were hand-engraved, making each one a unique piece of craftsmanship. Master engravers would spend days or even weeks carving medal designs into steel using gravers and chisels.

Modern Use:
Though still used for artistic and limited-edition medals, manual engraving has largely been replaced by automated methods due to its time-consuming nature.

Advantages:

• High artistic value

• Ideal for custom, small-batch production

• Deep and clear detail

 3. Electro-Erosion Dies 

Definition:
Electro-erosion or EDM (Electrical Discharge Machining) dies are produced by using electrical sparks to erode the metal and carve detailed shapes into the die.

Modern Use:
EDM became popular in the late 20th century, allowing manufacturers to create complex die shapes with high precision, especially for hard metals or detailed micro-markings.

Advantages:

• Excellent for hard materials

• High precision without mechanical stress

• Useful for fine or recessed patterns

 4. CNC Precision Engraving Dies 

Definition:
CNC engraving dies are made using computer-controlled milling machines. These machines use digital design files (CAD/CAM) to carve extremely detailed and precise medal dies.

Modern Use:
This is the current standard in die production. CNC machines ensure accuracy, repeatability, and efficiency, making them ideal for both bulk and high-end custom medals.

Advantages:

• Digital accuracy and repeatability

• Highly efficient and consistent

• Easily modified for design updates

• Compatible with both metal and non-metal dies

 Summary Table:

1.3, Steel (e.g., Cr12, HRC), copper, tungsten carbide, etc

Materials Used in Medal Dies

Creating a medal die requires materials that can endure high pressure, maintain fine detail, and resist wear over time. The most commonly used materials include tool steel, copper alloys, and tungsten carbide. Here’s a breakdown:

1. Tool Steel (e.g., Cr12, D2, HRC 58-62)

• Description: Cr12 is a high-carbon, high-chromium tool steel, often compared with D2 steel.

• Hardness: After heat treatment, it reaches a hardness of HRC 58–62.

• Applications: Widely used for stamping and embossing dies due to its excellent wear resistance and toughness.

• Advantages:

  • Holds sharp edges well for detailed engraving.

  • High durability even under frequent high-pressure stamping.

• Disadvantages:

  • Requires precise heat treatment.

  • Prone to cracking if improperly handled.

2. Copper and Copper Alloys (e.g., Red Copper, Brass)

• Description: Copper-based materials are softer and more malleable, suitable for lighter-duty die work or for making mold inserts.

• Applications:

  • Often used in the production of commemorative medals or decorative molds.

  • Ideal for electroforming or electro-erosion (EDM) electrodes.

• Advantages:

  • Easy to machine or engrave.

  • Good electrical conductivity (for EDM applications).

• Disadvantages:

  • Low wear resistance — not suitable for high-volume stamping.

  • Deforms under high pressure.

3. Tungsten Carbide

• Description: A composite of tungsten and carbon, sintered with cobalt or nickel.

• Hardness: Extremely hard — often above HRC 70.

• Applications:

  • Used for high-volume, high-precision stamping dies.

  • Ideal for coin dies or mass medal production.

• Advantages:

  • Extremely high wear resistance.

  • Long service life — can stamp tens or hundreds of thousands of medals.

• Disadvantages:

  • Brittle — prone to cracking if impacted.

  • High cost and difficulty in machining.

Material Selection Guide (Based on Application)

1.4，Processing methods: CNC engraving, EDM, laser engraving, etc

• Upper Die and Lower Die: These are the primary stamping surfaces that press the metal blank to form the desired medal design.

• Die Base: Supports and aligns the die to ensure consistent pressure distribution during operation.

• Guide Pillars and Guide Bushings: Ensure precise vertical alignment and smooth motion between the upper and lower dies.

• Die Cavity: The engraved design area that contains the detailed artwork or text to be transferred onto the medal surface.

• Ejector Mechanism (if applicable): Used to automatically release the finished medal after stamping or casting.

2.1, Positive and negative die structure

Positive and Negative Die Structure in Medal Making

In medal production, dies are typically made in pairs—a positive (male) die and a negative (female) die. These two work together in a press to form the design onto a metal blank. Each has distinct characteristics and functions:

Positive Die (Male Die)

• Function: Raised parts of the design; it projects outward.

• Application: Presses into the metal blank to create recessed (engraved) features on the medal.

• Structure: Carved in relief—the details of the artwork stand out from the die surface.

• Material: Usually made from high-hardness steel (e.g., Cr12, HRC-treated) to withstand repeated impact.

Negative Die (Female Die)

• Function: Recessed parts of the design; it receives the impression.

• Application: Forms the raised (embossed) details on the medal by supporting the blank from below.

• Structure: Engraved or etched inward—creating cavities that match the male die’s protrusions.

• Material: Also made from hardened steel, but occasionally copper or tungsten carbide is used for special applications.

Die Alignment and Precision

To ensure perfect image transfer and avoid misalignment during stamping, positive and negative dies are mounted with guide posts and bushings that maintain precise alignment during pressing.

Summary

The interplay between the positive and negative dies is essential in medal production. The male die pushes the design into the blank while the female die supports the metal and shapes the opposite side, ensuring crisp, consistent detailing. This dual-die structure remains a cornerstone of both traditional hand-engraved and modern CNC-manufactured dies.

2.2, Mold fastening method (screw fastening, guide pin alignment)

Here’s a summary paragraph that includes both the introduction and key details about Medal Die Structure and Components, including positive and negative die structure and mold fastening methods:

Medal Die Structure and Components

A medal die is a precision tool used to imprint or shape medals with intricate designs, inscriptions, and textures. The structure of a medal die typically consists of two main parts: the positive die (male die) and the negative die (female die). The positive die features raised elements that correspond to the recessed areas of the medal, while the negative die contains recessed engravings that form the raised features on the final product. These dies are tightly aligned and held together during stamping or casting.

To ensure stability and precision during operation, mold fastening methods such as screw fastening and guide pin alignment are used. Screw fastening secures the dies firmly to the machine base, while guide pins ensure perfect alignment between the two dies, preventing misprints and maintaining consistency in high-volume production. This structural design is critical for achieving fine detail and consistent quality in medal manufacturing.

Medal dies are engineered for high precision, durability, and customization to meet the demands of both large-scale production and bespoke medal creation. Key features include high hardness and wear resistance, often achieved through the use of premium materials such as Cr12 steel, tungsten carbide, or copper, and heat treatment processes like quenching for extended die life. The dies support fine engraving capabilities, including CNC precision engraving, EDM (electro-discharge machining), and laser engraving, ensuring intricate textures and details are faithfully replicated on the medal surface.

Medal dies can be made in positive and negative pairs and are fitted using screw-fastening and guide pin alignment for stability and repeatability during stamping. Additionally, the die surfaces can be tailored to accommodate custom logos, personalized inscriptions, and artistic patterns, making them suitable for commemorative, military, academic, and corporate medals.

3.1, High-precision pattern reproduction

3.2, Long life and high wear resistance

Medal dies are engineered for durability and prolonged operational life, even under the high-pressure conditions of repeated stamping. This is achieved through the use of premium-grade materials such as Cr12 tool steel, tungsten carbide, and hardened copper alloys, which offer excellent hardness and toughness. Many dies undergo heat treatment to reach hardness levels of HRC 58–62, significantly enhancing their resistance to wear, deformation, and fatigue. As a result, medal dies can maintain sharp edges and precise detail across thousands of production cycles, ensuring consistency and reducing downtime for maintenance or replacement. This makes them ideal for mass production of commemorative medals, military decorations, and custom award pieces, where consistent quality and long-term reliability are essential.

3.3, Customizable with personalized designs and text

Medal dies offer extensive customization options to meet the unique needs of clients and projects. They can be crafted to include personalized designs, logos, inscriptions, and text, enabling the production of highly distinctive medals and commemorative pieces. Using advanced technologies such as CNC engraving, laser engraving, and electro-erosion (EDM), manufacturers can accurately reproduce intricate patterns, fine details, and custom lettering onto the die surface. This level of customization allows organizations to create medals that reflect specific themes, events, or branding requirements, whether for sports awards, corporate recognition, military honors, or special celebrations. Personalized dies ensure each medal carries meaningful, high-quality imagery and text, enhancing the sentimental and aesthetic value of the final product.