Common Badge Manufacturing Processes
Stamping Process
This process can create simple embossed or recessed effects, resulting in a good metallic texture. The surface can be electroplated in various colors.
Working Principle: After engraving the stamping die, high pressure is used to press the design onto the metal sheet from top to bottom. A cutting tool then separates the badge from the metal sheet.
Materials: Stamped badges are generally made of copper, iron, aluminum, etc., hence the name "metal badges." Copper badges are the most common because copper is relatively soft, producing the clearest lines. Iron badges are next best, but copper is also more expensive.
Advantages: Perfect metallic texture, smooth surface. Supports glossy, matte, and colored finishes.
Precautions: If the product is three-dimensional, excessive pressure during stamping can cause the metal to crack. Suitable for simple embossed or recessed products.
Die Casting Process
This process can cast various three-dimensional products, and the surface can be electroplated in various colors.
Working Principle: The die-casting mold is engraved, and both sides are fixed to the machine and closed. Molten metal is poured into the mold and cooled to solidify. Supports color filling, hollowing, and relief engraving.
Material: Die-cast badges typically use zinc alloy. Due to its low melting point, zinc alloy, when heated and poured into the mold, allows for the creation of complex and challenging relief and hollowed-out badges. Advantages: Products can be made very three-dimensional, suitable for medals, badges, commemorative medals, etc., with strong three-dimensional shapes.
Painting Process:
The finished product has a raised texture, and the surface can be electroplated with various colors. Recessed areas can be filled with various colors.
Working Principle: The painting process builds upon die-casting and stamping processes. Pigment is injected into the recessed areas using a coloring machine, and then baked to set the color.
Material: Generally includes copper, zinc alloy, and iron. Iron and zinc alloy are cheaper, so they are commonly used in painted badges. Advantages: Can be filled with various colors. Precautions: One recess per color, with each color area surrounded by a metal wire.
To prolong the lifespan of painted badges and prevent scratches, a layer of transparent protective resin, known as polyresin or epoxy resin, is applied to its surface. After applying the resin, the badge loses the textured feel of metal. However, polyresin is also easily scratched, and over time, exposure to air, oxidation, and ultraviolet radiation can cause it to yellow.
