Die-Struck vs Die-Cast Medals and Coins: Which Process Is Best?

Die-striking and die-casting are two common manufacturing processes for custom medals and challenge coins. Each has its own strengths, and choosing the right one depends on your design, quantity, and budget.

What Is Die-Struck?

Die-striking uses a high-pressure press to stamp a design into a metal blank. The result is a raised and recessed metal design with sharp detail. Die-struck products are often left without color or filled with soft enamel. This process is ideal for classic coins, medals, and pins with flat designs.

What Is Die-Cast?

Die-casting injects molten metal into a mold under pressure. It allows for 3D designs, complex shapes, and deeper details than die-striking. Die-casting is commonly used for medals with cutouts, challenge coins with sculptural relief, and products with irregular shapes.

Comparison Table

Feature	Die-Struck	Die-Cast
Best for	Flat designs, fine lines	3D designs, complex shapes
Detail level	Excellent for 2D	Excellent for 3D
Weight	Heavier, denser	Lighter
Mold cost	Lower	Higher
Minimum order	Lower	Higher
Typical uses	Classic coins, simple medals	3D challenge coins, shaped medals

Which Process Should You Choose?

Choose die-striking if your design is primarily 2D with fine text and lines, or if you want a classic metal look. Choose die-casting if your design has 3D elements, complex shapes, or deep relief. For most sports medals and simple designs, die-striking is sufficient. For military challenge coins and commemorative pieces with logos that pop, die-casting is usually better.

Conclusion

Both processes produce high-quality products. The best choice depends on your artwork. Send your design to a custom medal manufacturer and ask which process they recommend.