HOW IS IT MADE
Step 0: DESIGN
Of course, every medal begins on the designer’s table, which is drawn up according to the vision of our clients in many cases. We work based on concepts briefly presented via phone, sketches and sausages-like horses drawn onto a foolscap, but sometimes relying on digitally
drawn sketches too. Do not worry about it, we understand and feel what You have dreamed. 😉
Step 1: MOULD
If You accepted the production design, a mould is made, which is the perfect inverse of the prospective race medal. This is made of a specially strong material, that is resistant to the hot zinc-allow poured into it.
Step 2: MOULDING
Using the ready moulds, we mould your prospective medal. We recycle the unused base material and the residues chipped-down (next step) from the previously produced medals. This is the less wanted task, since we heat up the base material to a temperature of about 420 °C.
Step 3: CHIPPING
We were thinking about how to describe this process, but we call like this, although some call it shredding… So the goal is to make smaller-bigger metal surfaces on the medal’s side, since these are those channels, where the material heated up to the melding point reaches the mould. We recycle the chipped-down pieces later.
Step 4: GRINDING
After we have taken down the major metal pieces, grinding may begin, which is a much more precise process. From the very thick grinding head to the miniatures, all tools are available to our colleagues who are more skillful than some surgeons, who do not release any medal with trims.
Step 5: POLISHING
Now the medal is ready, the raw metal is very nice, particularly after leaving the polishing process. There was an example on that our client requested unfinished raw medals – not a bad choice…
Step 6: GALVANIZATION
Here comes finishing, whether your medal shall be gold or silver. Galvanization is a great invention, briefly this means that we separate metal coat in the liquid (positive pole, anode) using electrolysis, that stick to the negative pole (i.e. cathode, in this case the poor race medals).