Common Medal Design Mistakes: 15 Errors to Avoid Before Manufacturing Custom Medals

Ordering custom medals should be an exciting experience. Whether you are organizing a marathon, hosting a corporate awards ceremony, or commemorating a special event, a well-designed medal can leave a lasting impression. However, many buyers—especially first-time purchasers—make costly design mistakes that result in disappointing finished products, budget overruns, or even the need for a complete re-production.

At Morning Craft, we have manufactured thousands of custom medals for clients worldwide. Through years of experience, we have seen the same errors repeated again and again. In this comprehensive guide, we will walk you through 15 common medal design mistakes and show you exactly how to avoid them. By the end of this article, you will have the knowledge and tools to design a custom medal that looks professional, feels premium, and stays within your budget.

How to Design a Custom Medal Correctly: A Step-by-Step Process

Before diving into the mistakes, let us first establish the correct process for designing a custom medal. Following these steps will help you avoid most of the errors we discuss below.

Step 1: Define the Purpose of the Medal

Every medal serves a different purpose, and understanding yours is the foundation of good design. Common purposes include:

• Sports competition – Requires bold, readable designs visible from a distance
• Marathon or race – Often incorporates distance, year, and event branding
• School award – Should feel prestigious yet age-appropriate
• Corporate recognition – Needs to reflect brand identity and professionalism
• Commemorative event – Focuses on storytelling and emotional connection
• Promotional or collectible medal – May prioritize uniqueness and display value

Knowing the purpose helps you make informed decisions about size, material, color, and complexity.

Step 2: Choose the Right Medal Size and Shape

Medal size directly affects visual impact and cost. Standard medals range from 50mm to 70mm in diameter, but custom shapes can make your medal stand out. Consider who will receive the medal and how it will be displayed. A marathon medal might benefit from a larger size, while a corporate award may call for a more refined, compact design.

Step 3: Simplify the Artwork for Manufacturing

This is where most mistakes begin. Digital designs do not always translate well into metal. Simplify your artwork by removing overly fine details, ensuring adequate spacing between elements, and thinking in terms of raised and recessed areas rather than flat graphics.

Step 4: Select Materials and Manufacturing Methods

Your choice of material and production method affects detail reproduction, weight, durability, and cost. We will discuss this in depth in Mistake #6 below.

Step 5: Choose Colors and Plating

Colors and plating define the visual character of your medal. Select options that complement each other and suit the occasion.

Step 6: Design the Ribbon and Attachment

The ribbon is often overlooked, but it contributes significantly to the overall presentation. Choose colors that complement the medal and consider the attachment style (loop, split ring, or custom connector).

Step 7: Review the Production Artwork Before Approval

Never approve artwork without a thorough review. Check spelling, colors, proportions, and manufacturability. This single step can save you from expensive rework.

The 15 Common Medal Design Mistakes

Mistake #1: Using Text That Is Too Small

One of the most frequent errors we see is text that looks fine on screen but becomes illegible once manufactured. Metal casting has physical limitations. As a general rule, keep text at a minimum height of 1.5mm to 2mm for readability. If your design includes names, dates, or event titles, ensure they are large enough to be clearly read on the finished medal.

Mistake #2: Overcrowding the Design

Less is more in medal design. A crowded medal with too many elements—logos, text, images, borders—creates visual confusion and makes manufacturing difficult. Focus on one or two key elements and give them room to breathe. White space (or in this case, unadorned metal space) is your friend.

Mistake #3: Insufficient Contrast

Without proper contrast between raised and recessed areas, a medal looks flat and unimpressive. Ensure there is clear differentiation between background and foreground elements. This applies to both the metalwork and any enamel color fills.

Mistake #4: Ignoring the Minimum Line Width

Very thin lines may disappear during the casting or stamping process. As a guideline, lines should be at least 0.3mm to 0.5mm wide depending on the manufacturing method. Always confirm minimum line requirements with your manufacturer before finalizing the design.

Mistake #5: Making Raised and Recessed Areas Too Complicated

Understanding the difference between 2D and 3D medal designs is crucial. In a 2D medal, the design is flat with clear raised and recessed areas separated by metal borders. In a 3D medal, the surface has varying depths and sculptural elements.

Common problems caused by excessive depth differences include:

• Uneven enamel filling in recessed areas
• Weak spots that are prone to breaking
• Loss of detail in deep recesses
• Inconsistent plating coverage

How relief design affects shadows and visual contrast:

The depth between raised and recessed areas creates natural shadows that define your design. Too little depth makes the design look flat; too much depth can create harsh shadows that obscure details. A professional manufacturer can advise on optimal depth ratios.

When a 3D medal is worth the additional complexity and cost:

3D medals are ideal for commemorative pieces, high-end awards, and situations where visual impact justifies the higher price. For standard sports medals or bulk orders, a well-executed 2D design often delivers better value.

Mistake #6: Choosing the Wrong Metal Material

Material selection is one of the most important decisions in medal manufacturing. Here is a comparison of common options:

Material	Weight	Detail Reproduction	Durability	Price Range
Zinc Alloy	Medium	Excellent	Good	Low to Medium
Iron	Heavy	Good	Very Good	Low
Brass	Heavy	Very Good	Excellent	Medium to High
Stainless Steel	Heavy	Good	Excellent	Medium

How material affects your medal:

• Weight – Heavier medals feel more premium but cost more to ship
• Durability – Iron and brass resist wear better over time
• Detail reproduction – Zinc alloy captures fine details exceptionally well due to its casting process
• Price – Iron is typically the most budget-friendly, while brass commands a premium

Why the cheapest material is not always the most cost-effective:

Choosing the cheapest option may result in poor detail reproduction, faster tarnishing, or a medal that feels insubstantial. Sometimes spending slightly more on material saves money by reducing defects and re-orders.

Mistake #7: Selecting Colors That Do Not Work Well with Metal

Not all color combinations translate well to metal surfaces. Here is what you need to know:

• Why some color combinations lose impact on a metal medal: Bright neon colors, for example, may look vibrant on screen but appear washed out or artificial when applied as enamel on metal. Similarly, very light colors can disappear against silver or gold plating.
• How enamel colors interact with plating finishes: Dark enamel colors pop against gold plating, while lighter colors tend to stand out more against silver or nickel finishes. Always consider the combination, not just individual elements.
• Common contrast problems between metal borders and colored areas: If your enamel color is too close to the plating color, the design will lack definition. For example, yellow enamel on gold plating creates almost no contrast.
• Tips for choosing colors that remain visually strong: Request physical color samples from your manufacturer. Pantone color matching is standard in the industry, but always verify with a physical reference when possible.

Mistake #8: Using Too Many Colors and Increasing Production Costs Unnecessarily

Each additional enamel color adds to the production cost because each color requires a separate filling step. Here is how to manage this:

• How the number of enamel colors affects pricing: Most manufacturers charge per color. Going from 3 colors to 6 colors can increase your unit cost by 20-40%.
• When multiple colors genuinely improve the design: If your brand identity or event theme requires specific colors, do not compromise. The key is intentionality.
• How to simplify the color palette without losing brand identity: Use your primary brand color as the dominant fill and limit accent colors to one or two. Consider using the metal plating itself as a "color" in the design.
• Smart ways to create a premium appearance with fewer colors: Antique finishes, dual-tone plating, and strategic use of negative space can create a luxurious look with minimal color fills.

Mistake #9: Choosing the Wrong Plating Finish

Plating is the final metal surface treatment that defines your medal's overall look. Popular options include:

• Gold – Classic, prestigious, warm tone
• Silver (Nickel) – Clean, modern, versatile
• Antique Gold/Silver/Bronze – Vintage, textured, dimensional
• Black Nickel – Dramatic, modern, high contrast
• Rose Gold – Trendy, elegant, distinctive

How plating changes the overall appearance:

The same design can look completely different with different plating. Antique finishes add depth and shadow to recessed areas, while bright finishes create a clean, polished look.

Matching plating with the event theme:

A corporate tech award might suit silver or black nickel. A traditional sports championship calls for gold. A vintage-themed event benefits from antique bronze.

Common plating choices that reduce design contrast:

Using a bright gold plating with minimal depth difference in the design can make the medal look flat. In such cases, an antique finish adds the contrast needed to bring the design to life.

Mistake #10: Ignoring the Importance of Medal Thickness and Weight

This is a mistake that affects how the medal feels, which is just as important as how it looks.

• Why a medal can feel cheap even when the artwork looks excellent: A thin, lightweight medal feels insubstantial in the hand, regardless of how beautiful the design is. Recipients associate weight with value.
• How thickness affects durability and perceived quality: Thicker medals resist bending and feel more substantial. Standard thickness ranges from 3mm to 5mm, with premium medals going up to 7mm or more.
• Balancing a premium feel with shipping costs: Heavier medals cost more to produce and ship. Find the sweet spot where the medal feels quality without breaking your logistics budget.
• Choosing the right weight for different purposes: Sports medals for large events typically range from 30g to 60g. Commemorative or premium awards can go from 80g to 150g or more.

Mistake #11: Neglecting the Ribbon Design

The ribbon is the first thing people see when the medal is worn or displayed. A poorly chosen ribbon can undermine an otherwise excellent medal. Match ribbon colors to the event theme, ensure the width is proportional to the medal size, and choose quality fabric that will not fray easily.

Mistake #12: Not Accounting for Production Lead Time

Many buyers wait too long to place orders, leaving insufficient time for sampling, revisions, and production. Custom medals typically require 15-30 days for production after artwork approval, plus shipping time. Always plan at least 6-8 weeks before your event.

Mistake #13: Not Designing Both Sides of the Medal Properly

Many buyers focus entirely on the front of the medal and neglect the back. Here is how to approach double-sided design:

When a single-sided medal is enough:

For budget-conscious orders, large-quantity sports events, or when the back will not be visible during presentation, a single-sided medal with a plain or textured back is perfectly acceptable.

Advantages of double-sided custom medals:

• Additional space for information (event details, sponsor logos, serial numbers)
• More premium feel and perceived value
• Better for commemorative and collectible purposes

What information belongs on the front versus the back:

The front should carry the primary visual impact—event logo, main imagery, or symbolic design. The back is ideal for text-heavy content: event name, date, location, participant category, or sponsor acknowledgments.

How backside designs can add value without overcrowding the front:

Moving secondary information to the back allows you to keep the front clean and impactful. This is especially useful for medals with complex artwork or multiple sponsor requirements.

Mistake #14: Copying a Digital Design Directly Without a Production Review

This is perhaps the most critical mistake for first-time buyers.

Why artwork may look different after becoming a physical metal product:

Screens display designs in flat, backlit color. Metal medals rely on physical depth, shadow, and reflected light. What looks sharp and vibrant on screen may appear muddy or indistinct in metal.

Common differences between screen colors and finished enamel:

• Colors may appear slightly darker or more muted in enamel
• Metallic inks or gradients cannot be replicated in standard enamel
• Very fine gradients must be converted to solid color blocks

Why borders, lines, and spacing may need adjustment:

On screen, a 0.2mm gap between elements looks fine. In metal, that gap may fill with enamel bleed or disappear entirely. A production review ensures all elements meet minimum spacing and width requirements.

The importance of a professional artwork review before production:

At Morning Craft, we provide a free production artwork review with every order. Our engineers check your design for manufacturability, suggest adjustments, and provide a digital proof before any molds are created. This step alone prevents the majority of design disappointments.

Mistake #15: Failing to Verify All Order Details Before Production

Before giving final approval, double-check every detail. A single misspelled word or incorrect color code can render an entire production run useless.

A Quick Checklist: What to Check Before Ordering Custom Medals

Save this checklist and use it every time you place a medal order:

Design Checklist

• Is the text large enough to read? (Minimum 1.5mm–2mm height)
• Are small details manufacturable? (Minimum line width 0.3mm–0.5mm)
• Is the design too crowded? (Can elements be removed without losing meaning?)
• Does the design have enough contrast? (Clear difference between raised and recessed areas)

Manufacturing Checklist

• Is the material suitable for the purpose and budget?
• Is the medal thick enough to feel quality? (Minimum 3mm recommended)
• Is the manufacturing process appropriate? (Die casting, stamping, or printing)
• Are raised and recessed areas clearly defined?

Final Order Checklist

• Correct size
• Correct colors (verified with Pantone codes)
• Correct plating
• Correct ribbon (color, width, attachment style)
• Correct spelling (check all text carefully)
• Correct quantity (including a small buffer for replacements)

How Common Medal Design Mistakes Affect Cost

This section is particularly valuable for potential buyers who are working within a budget. Design mistakes do not just affect quality—they directly impact your bottom line.

Mistake	Cost Impact
Too many colors	+0.05– 0.15 per color per unit
Unnecessary 3D complexity	+20%–50% mold cost
Wrong material choice	May require full re-order
Spelling errors discovered after production	100% re-production cost
Insufficient thickness requiring redesign	New mold + production cost
Design not manufacturable	Redesign fees + delayed timeline

The most expensive mistake is the one that requires re-production. A single spelling error on a 5,000-piece order can cost thousands of dollars to fix. This is why the final review step is not optional—it is essential.

Pro tip: Investing 30 minutes in a thorough design review can save you weeks of delay and significant unexpected costs. Always request a physical sample before approving bulk production, especially for large orders.

Final Thoughts

Designing a custom medal is both an art and a science. The best-looking designs on paper do not always make the best physical medals. By understanding the manufacturing process, respecting material limitations, and following the checklists above, you can ensure your custom medals turn out exactly as you envisioned.

At Morning Craft, we are more than a manufacturer—we are your design partner. Our team reviews every artwork for producibility, offers material and finish recommendations, and provides free digital proofs before production begins. Whether you need 50 medals or 50,000, we help you avoid these common mistakes and deliver a product you will be proud to present.

Ready to start your custom medal project? Contact us today for a free quote and design consultation.

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