Precision Badges and Medals

The badges and medals we make, when not die-struck, use an injection moulding process. Metal injection moulding combines the material flexibility of powder metallurgy with the strength and integrity of machined, pressed or otherwise manufactured small, complex, metal parts and the design flexibility of highly detailed design moulding. The injection moulding process is ideally suited to producing small and complex-shaped pieces (badges or medals) with outstanding strength and detail properties. 

The process involves combining fine metal powders with plastic binders which allow the metal to be injected into a precision mould using equipment similar to standard plastic injection moulding machines. After the piece is moulded and before the binders are removed, the piece is referred to as green. The next step is to remove the binders with solvents and thermal processes. The resultant metal badge or medal is sintered at temperatures great enough to bind the particles but not melt the metal. 

The products made through metal injection moulding are used in a broad range of applications (including badge and medal work, defence, medical, dental, firearms, aerospace, and automotive). The difficulty of fabrication through other means may make it inefficient or even impossible to manufacture otherwise. Increasing complexity for traditional manufacturing methods typically does not increase cost in a metal injection moulding operation due to the wide range of features possible utilising the process.

Essentially, with its inherent design flexibility, precision injection moulding is capable of producing an almost limitless array of highly complex designs in many different alloys ranging from stainless steels, alloy steels, and soft magnetic materials, controlled expansion materials, and custom metal alloys. Design and economic limitations of traditional metalworking technologies, like machining and casting, can be readily overcome by injection moulding.

Reverse Mould

Obverse Mould

Moulded Badge

Completed Badge