Custom Crafts Blog
Creating Custom Plastic Medallions: A Complete Guide to Design and Production
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When organizations need affordable, durable recognition pieces, custom plastic medallions offer an excellent solution. These versatile awards work well for everything from sports tournaments to corporate events, providing a professional appearance without the cost of metal alternatives.
What Are Custom Plastic Medallions?
Custom plastic medallions are commemorative pieces made from molded or printed plastic materials. Unlike traditional metal medals, they’re lightweight, cost-effective, and can be produced in virtually any color or design. Most feature a circular or shield shape with custom artwork, text, or logos on one or both sides.
The materials used typically include acrylic, PVC, or polystyrene. Each offers different characteristics: acrylic provides a glass-like clarity, PVC delivers flexibility and durability, while polystyrene works well for budget-conscious projects.
Why Choose Plastic Over Metal?
Several practical reasons make plastic medallions an attractive choice:
Budget-friendly production: Plastic manufacturing costs significantly less than metal casting or stamping, especially for orders under 500 units. This makes them ideal for youth sports leagues, schools, and community organizations working with limited budgets.
Weather resistance: Unlike some metals that tarnish or rust, quality plastic medallions maintain their appearance when exposed to moisture or outdoor conditions. This durability proves valuable for events like charity runs or outdoor competitions.
Lightweight comfort: Athletes and recipients appreciate that plastic medallions won’t weigh down clothing or cause discomfort when worn for extended periods during ceremonies or photos.
Design flexibility: Digital printing and molding techniques allow for full-color graphics, intricate details, and even 3D relief elements that would be prohibitively expensive in metal.
Personal Experience with Tournament Medallions
Last year, I helped organize a youth soccer tournament that needed 150 participation medallions. After comparing metal and plastic options, we chose custom plastic medallions with full-color printing. The decision proved worthwhile—the kids loved the bright colors featuring our tournament logo, and several parents mentioned how the lightweight design meant their children actually wore them home instead of immediately putting them in bags. The total cost came in 40% lower than the metal quote, allowing us to redirect funds toward better field equipment.
Design Considerations
Creating effective custom plastic medallions requires attention to several elements:
Size and shape: Standard sizes range from 2 to 3 inches in diameter, though custom shapes can accommodate specific themes. Consider how the medallion will hang and whether the design works at that scale.
Color selection: Digital printing allows unlimited colors, but simpler designs with 2-4 main colors often create stronger visual impact. High contrast between background and text ensures readability.
Text readability: Keep text large enough to read comfortably. Generally, nothing smaller than 8-point type should appear on a 2.5-inch medallion.
Attachment method: Most medallions include a hole for ribbon or a bar pin backing. Consider how recipients will display or wear the piece.
Production Methods
Two primary techniques create plastic medallions:
Injection molding: This method involves creating a metal mold and injecting molten plastic under pressure. It works best for orders over 500 units due to mold costs, but produces highly detailed 3D designs with crisp edges.
Digital printing and cutting: For smaller runs, designs are printed on plastic sheets and cut to shape. This approach offers faster turnaround and lower setup costs, making it ideal for one-time events.
Some manufacturers combine both techniques, molding the base shape and adding printed overlays for color detail.
Customization Options
Beyond basic design, several enhancements can elevate your medallions: for example, knowing how to clean medals and ribbons can keep them looking their best.
Glitter or metallic finishes that catch light
Translucent or frosted materials for unique visual effects
Dual-layer construction with contrasting colors
Insert medals where a printed center fits into a molded frame
Individual numbering or personalization for each recipient
Ordering Process and Timeline
Most suppliers require 2-4 weeks for production, depending on quantity and complexity. The typical workflow includes:
Submit artwork or work with the supplier’s design team
Review and approve digital proofs
Production of samples (optional but recommended for large orders)
Full production run
Quality inspection and packaging
Shipping
Rush services exist but usually add 20-30% to costs. Plan ahead when possible.
Quality Factors to Evaluate
Not all plastic medallions deliver the same quality. Evaluate samples for:
Print clarity: Colors should be vibrant with sharp edges, not blurry or washed out.
Material thickness: Quality medallions typically measure 2-3mm thick. Thinner pieces feel cheap and may warp.
Finish consistency: Check for even surface texture without bumps, bubbles, or rough edges.
Attachment durability: Holes should be reinforced, and any attachments should connect securely.
Practical Applications
Custom plastic medallions serve numerous purposes:
Youth sports participation awards and tournament prizes
Employee recognition programs and service anniversaries
Fundraising campaigns and donor appreciation
Trade show giveaways and promotional items
School achievement awards and perfect attendance recognition
Commemorative pieces for special events or milestones
Cost Expectations
Pricing varies based on size, quantity, and complexity, but general ranges help with planning:
Simple single-color designs: $1-2 per piece for 100+ units
Full-color printed medallions: $2-4 per piece for 100+ units
Complex 3D molded designs: $3-6 per piece for larger quantities
For more detailed information on the cost to customize a medal, including influencing factors and options, see our guide.
Volume discounts typically kick in at 250, 500, and 1,000 units. Always request quotes from multiple suppliers, as pricing can vary significantly.
Storage and Distribution
Plastic medallions, as well as old medals, store easily without special conditions. Keep them in boxes or bags away from direct sunlight to prevent any color fading over time. For events, consider presentation options like small gift bags or display boxes that add perceived value.
Environmental Considerations
Some manufacturers now offer recyclable plastic materials or bio-based alternatives. If environmental impact concerns your organization, ask about sustainable options. While these may cost slightly more, they align with eco-conscious values.
Conclusion
Custom plastic medallions provide an affordable, flexible solution for recognition needs across many settings. Their durability, design possibilities, and cost-effectiveness make them particularly valuable for organizations that need quality awards without excessive budgets. By understanding the production process, design principles, and quality factors, you can create medallions that recipients will value and display with pride.
Whether you’re planning a small company event or a large tournament, plastic medallions deliver professional results that honor achievements while respecting budget constraints.
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