Medal Size Chart
Choosing a medal size fixes three things at once: how much artwork the face can hold, how the medal feels in the hand, and what it costs to make and ship. This chart gives the metric diameter, the thickness we can produce and the weight in grams for die-cast zinc alloy medals, so you can specify a size without guessing.
Medal Sizes at True Scale
The circles below are drawn to scale against each other, so the size difference is what a recipient actually sees. Most orders land on 2 inches; anything from 2.5 inches up reads as a premium or commemorative piece.
Swipe to compare the larger sizes →
Drawn to scale, relative to each other — screen scaling means the absolute size on your display is not physical. The 4 inch medal is roughly seven times the face area of a 1.5 inch medal.
Medal Weight by Size
These bars are the weight of a 3 mm medal at each diameter — the thickness most orders are quoted at. Weight grows faster than diameter, because it follows the area of the face.
Standard Medal Sizes, Thickness and Weight
| Diameter | Metric | Thickness | Weight | Typical use |
|---|---|---|---|---|
| 1.25" | 31.8 mm | 2–3 mm | 9–15 g (0.3–0.5 oz) | Lapel-size, budget giveaways, coin charms |
| 1.5" | 38.1 mm | 2.5–3.5 mm | 18–26 g (0.6–0.9 oz) | High-volume races, school events, promotional pieces |
| 1.75" | 44.4 mm | 3–4 mm | 29–39 g (1.0–1.4 oz) | Unit coins, club awards, age-group medals |
| 2" | 50.8 mm | 3–5 mm | 37–65 g (1.3–2.3 oz) | The default: road races, corporate awards, recognition |
| 2.25" | 57.2 mm | 3–5 mm | 47–83 g (1.7–2.9 oz) | Premium finisher medals, presentation awards |
| 2.5" | 63.5 mm | 3–5 mm | 58–102 g (2.0–3.6 oz) | Marathon finishers, VIP gifts, display pieces |
| 2.75" | 69.9 mm | 3–5 mm | 70–124 g (2.5–4.4 oz) | Large event medals, detailed 3D artwork |
| 3" | 76.2 mm | 3–5 mm | 83–147 g (2.9–5.2 oz) | Statement awards, charity gala, commemorative |
| 3.5" | 88.9 mm | 3–5 mm | 113–200 g (4.0–7.1 oz) | Wall plaques, oversized keepsakes |
| 4" | 101.6 mm | 3–5 mm | 148–261 g (5.2–9.2 oz) | Trophies on a ribbon, architectural awards |
| 5" | 127 mm | 3–5 mm | 230–409 g (8.1–14.4 oz) | Display centrepieces, ceremonial medals |
| 6" | 150 mm | 3–5 mm | 320–570 g (11.3–20.1 oz) | Showpieces, commemorative wall medals |
Swipe the table sideways to see all columns →
Weights are for die-cast zinc alloy, round medals with single-sided relief, and are the figures we use for quotation and freight estimates. Brass and copper are heavier at the same size; deep 3D relief, a raised rim or double-sided tooling adds weight. The final figure is confirmed against the sample.
What Thickness Changes
Diameter gets the attention, but thickness is the cheaper lever on feel. Using a 2 inch medal as the example:
| Thickness | Weight (2 inch) | Added weight |
|---|---|---|
| 3 mm | 37 g | — |
| 3.5 mm | 44 g | +7 g |
| 4 mm | 51 g | +14 g |
| 5 mm | 65 g | +28 g |
Swipe the table sideways to see all columns →
Going from 3 mm to 4 mm adds about 38 percent to the metal weight and turns a light medal into one that sits heavy in the palm. That is usually enough for a premium event; 5 mm is a deliberate statement and costs accordingly. On medals under 1.5 inches, 3 mm already looks thick, because the face is small relative to the edge.
Choose a Size by Use Case
Road races and finisher medals
2"–2.5" · 37–80 g
Enough room for a route line, year and sponsor marks without clutter. 2.5 inches is the usual step up for marathon finishers.
School and club awards
1.5"–1.75" · 22–39 g
Cost-efficient at volume, and light enough to hand out by the box. Engraved or printed inserts keep the artwork legible at this size.
Corporate recognition
2"–2.5" · 37–80 g
Holds a logo, a name and a year cleanly. Pairs with a presentation box as a desk piece rather than a wearable.
Commemorative and display
3"–6" · 83–570 g
Statement pieces for galas, anniversaries and wall displays. Plan the ribbon or stand at the same time — weight dictates both.
Size, Weight and Cost
Three costs scale with the size of the medal:
- Metal. Material follows the face area and thickness, so a 3 inch medal at 4 mm uses about five times the zinc of a 1.5 inch medal at 3 mm (115 g against 22 g).
- Tooling. Every diameter and shape needs its own die. Staying on a standard size such as 2 or 2.5 inches avoids a tooling charge — see what a medal mould costs.
- Freight. Couriers bill actual or volumetric weight, so the heaviest medals in an order usually set the shipping cost. If you are shipping air freight, weighing the size decision against the budget is worth doing early.
How to Specify and Measure
Send us the diameter in millimetres (or inches), the thickness you want, the metal, and whether the relief is single or double sided. If you are matching an existing medal, measure the outer rim across its widest point and the thickness at the rim rather than across the highest point of the relief. We will confirm against our die list before quoting.
Frequently Asked Questions
What is the most common custom medal size?
2 inches (50.8 mm) is the most common custom medal size. It carries a logo, a date and a place name without crowding, and it feels substantial without being heavy. 1.5 to 1.75 inches is used for high-volume or budget-sensitive events, and 2.5 to 3 inches for marathon finishers, gala awards and commemorative pieces.
How much does a custom medal weigh?
A 2 inch (50.8 mm) die-cast zinc alloy medal weighs about 37 g at 3 mm, 44 g at 3.5 mm, 51 g at 4 mm and 65 g at 5 mm. A 3 inch medal is 83 g at 3 mm and 115 g at 4 mm, and a 1.5 inch medal is 22 g at 3 mm. Weight scales with the area of the medal, so doubling the diameter roughly quadruples the weight at the same thickness.
How thick should a custom medal be?
3 mm is the working standard for most medals up to 2 inches, and it is what most orders are quoted at. Step up to 3.5 or 4 mm when the medal needs a premium, substantial feel or carries deep 3D relief; 5 mm is for heavy statement pieces. Small medals of 1.5 inches or less are usually made at 2.5 to 3.5 mm.
Does medal size affect the price?
Yes, in three ways: metal content rises with the area of the medal and its thickness, each diameter needs its own die, and heavier medals cost more to ship. Staying on a standard diameter such as 2 or 2.5 inches avoids an extra die and usually gives the best value per piece.
Can I order a diameter that is not on the chart?
Yes. We produce round medals from 31.8 mm (1.25 inches) up to 150 mm (6 inches) and can tool in-between or non-round shapes such as square, shield, star or custom outlines. A non-standard size simply needs a dedicated die, which we quote with the order.
Do heavier medals cost more to ship?
Yes. Air freight and express couriers bill on actual or volumetric weight, whichever is higher, so a 4 mm medal instead of 3 mm adds about 38 percent to the metal and to the parcel weight. For large events the difference across thousands of medals is worth calculating before you fix the size.
Are these weights valid for brass and copper medals?
No. The chart is for die-cast zinc alloy, which is the most common medal material. Brass and copper are denser and weigh more at the same diameter and thickness. Tell us the metal when you enquire and we will confirm the weight for your specification.
How do I measure a medal for a replacement order?
Measure across the widest point of the outer rim with callipers, in millimetres, and measure thickness at the rim rather than across the highest relief. Send both numbers with a photo, and we will match the existing die or come closest to it without a new tooling charge.
Ordering Custom Medals
Sino Awards produces custom medals in any diameter from 31.8 mm to 150 mm, in zinc alloy, brass, copper or iron, with soft enamel, hard enamel, printing or 3D relief. Send your artwork and the size you have in mind and we will come back with a price, a weight and a sample plan.
Related Reading
- Challenge coin size chart — the same diameters for coins, with edge and pouch guidance.
- Custom medals — materials, finishes, ribbons and order process.
- What a medal mould costs — why staying on a standard size saves tooling.
- Plating options — finishes that change the look without changing the size.
