How to make zinc die casting medals

The first step is to draw the design of the custom meta.l then we input the
design into our die making computer and prepared to create the mold.
We clean our working table what you're seeing is a plank mold that we will cut and engrave. We're securing the bank mold in its proper position ,and installing the cutting tool that we will use to carve out the mold.
Mold-making is an artistic and complicated process. The quality of the mold directly affects the quality of the pin. Some detailed molds even need to be carved out over a period of several days.
We finished cutting the mold and are ready to move on to the next step. We aredeburring the mold to remove metal shavings and cleaning it out aftercarving.The process we're showing today is zinc casting. we're opening channelsto ease the flow of molten zinc into the mold .we carefully hand polish the front mold .We're giving the edge of the mold aquick polish to make it smooth. The next step in our mold creation is to polish
out the marks left by our cutting tools .

Now that the front mold is finished you can see the difference after the cuttingmarks are removed. We securely tighten then align the molds in our gravitycasting machine. Since this is a one-sided ,metal we will use a stock back mold. Once everything is lined up we engage the equipment and molten liquid zinc will flow into the mold once everything. Cools off the newlycasted metals are ready for the next step. 
We polished the edges to remove any burrs or other sharp areas and smooth out the surface. These are the raw zinc pin castings.we hand polish each edge to a smooth mirror like texture .

We organize, inspect ,and individually hand polish each medal.Our casted ,deburred, and highly polishedmetals are going to be electroplated .Each one is tied with copper wire to create a complete electric circuit.the first step to electroplating is making sure you have a clean surface .We're rinsing our metals in plain water prior to giving it an acid bath to prepare the surface to achieve a good chemical reaction.Repeated rinsing in plain water neutralizes and then removes the acid. We submerge the blanks in our copperplating bath. The purpose for copper is to increase electrical conductivity andimprove the durability of the final electroplated finish .After the copper is plated we rinse them thoroughly and place the metals into black plating.

While finishing the plating we're going to rinse the metals multiple times, then we'll bake them dry in our industrial oven .We organize our metals to get ready for the final polishing .We polish each side of every metal individually, by hand ,to inspect ourperfection and provide our distributors with the highest quality productsavailable .Our medals are now basically complete ,but we're going to seal the plating withone last process.We're going to spray clear lacquer on the front of the medalsto protect the finish plating and then bake them until dry.We'll use the same lacquer on the back and then place the medals back into theoven .
We've finished hand crafting our antique brass cast metals ,isn't it exciting .weinspect an individually poly bag each medal. presenting your finished medals .