The Manufacture of Medals
By Devery Sherman
Anyone who has held even the simplest military decoration or
medal in their hands has likely marvelled at its beauty. Most people would probably be
surprised, however, by both the number of processes and the degree of craftsmanship
involved in their construction.
As an employee of a US manufacturer holding a hallmark from the Department of the Army,
The Institute of Heraldry, I can only speak to the production of US federal medals, though
much of what I shall describe is universal.
In
the US, The Institute of Heraldry (TIOH) is charged with the approval and archiving of
specifications of every detail of medal and ribbon manufacture for federal military
awards. This begins with general specifications outlining the most basic features. Such
things as chemical composition of copper base alloys, plating thickness, and soldering are
defined, as well as what is expected in order to pass government inspection. Each medal in
turn has its own detailed specification in which the material to be used, dimension,
thickness, finish, and enamel (if any) are stated.
The design of each decoration and medal is an exact replica of
the design of the government die, if it is to be TIOH-approved. The vast majority of
medals are stamped from red brass. Gilding material contains a higher copper content and
is mainly though not exclusively (e.g. the Coast
Guard Distinguished Service Medal) used for medals with enamelling. The additional copper
allows the medallion to withstand the high temperatures required to fire enamel. Notable
exceptions include the Coast Guard Gold Life-Saving medal and Silver Life-Saving medal,
which are stamped from 24 Karat gold and 99 percent pure silver, respectively.
Thin strips of brass are die-struck, trimmed to shape, burrs removed, edges smoothed. A
hole is drilled in the lug to accommodate a jump ring for eventual mating to its proper
ribbon drape. Except for stamping, these refinements are accomplished by hand, one
medallion at a time. It is at this point that the medallions are sandblasted if a matte
finish is called for. Then the medals undergo a chemical degreasing and cleansing in order
to ensure an even finish.
Medals must be "surgically" clean prior to both enamelling and plating in order
for either to result in blemish-free surfaces. Not all pieces require polishing, or
enamelling, or plating; many go directly from cleaning to oxidation. Therefore, pieces not
being enamelled are sent to the polisher (if needed), or to the plater who then degreases
and cleans, then plates.
Enamelling (vitreous enamel) specifications, as all else, are
determined by TIOH. Color must match standard TIOH samples. Enamels are mixtures of
silica, lead oxides, salts of soda, potassium, and boric oxides. Colors are obtained by
adding various metallic oxides and/or stains. In general, powdered enamel is applied to
the metal surface, fired at temperatures around 1500 degrees F, allowed to cool,
"stoned" or abraded down with a carborundum to achieve a surface level with the
surrounding metal, and refired. The resulting surface is glossy, hard and glasslike.
From enamelling, the medallion progresses to polishing (for highlights, if required) and
electroplating. To pass TIOH inspection the pieces must exhibit no cut-through (no
underlying metal must be visible), blistered or peeling plating. A consistent finish is
desired. If the medal is to look "antiqued", it is placed in an oxidizing agent,
rendering it completely black. By mechanical means or by hand the majority of the
discoloration is removed leaving only enough to accent the piece. Finally, all pieces
except gold-plated items are spray-lacquered to preserve the finish and in the case of
silver-plated medallions, prevent any further natural oxidation or tarnishing.
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Copyright Hendrik Meersschaert 1998, 2000 ©