At Arliven, when we craft custom medals for our global clientele, one question frequently arises: How is such intricate detail and sharp relief achieved on a solid piece of metal?
The secret lies in a cornerstone of high-end manufacturing: Electrical Discharge Machining (EDM), often referred to as “spark machining.”
What exactly is EDM?
In simple terms, EDM is a non-contact manufacturing process that uses electrical energy to etch metal. Unlike traditional CNC milling, which relies on physical cutting tools, EDM creates a series of rapid, controlled electrical sparks between an electrode (usually copper or graphite) and the mold steel. These sparks generate intense heat that vaporizes the metal atom by atom, allowing us to “carve” designs with surgical precision.
Why EDM is Irreplaceable in Medal Manufacturing
For a custom medal, detail is everything. Here are three reasons why we utilize EDM technology at Arliven to ensure your awards stand out:
1. Conquering “Impossible” Geometries
Medal designs often feature sharp internal corners, ultra-fine text, or deep, complex textures. Traditional milling bits are limited by their own radius—they simply cannot reach into microscopic corners. EDM, however, mirrors the exact shape of the electrode, allowing us to replicate intricate 3D reliefs that would be impossible to achieve otherwise.
2. Maintaining Precision in Hardened Steel
To produce thousands of consistent medals—whether for a major marathon or a corporate gala—the molds must be made of incredibly hard, heat-treated steel. Because EDM involves no physical pressure (zero cutting force), it prevents the mold from deforming during the process. This ensures that the 1,000th medal we strike is just as crisp as the very first one.
Watch as Arliven’s EDM facility uses controlled sparks to erode hardened steel
3. Creating Premium Surface Textures
By adjusting the discharge parameters of the EDM machine, we can create various levels of “spark erosion” textures directly on the mold. This results in a sophisticated matte or velvet-like finish that is far more uniform and durable than chemical etching. It’s this subtle play of light and shadow that gives Arliven medals their premium, high-end feel.
The Arliven Craftsmanship Workflow
In our production cycle, EDM serves as the “master touch” in the finishing stage:
- 3D Modeling: Our designers translate your vision into a digital blueprint.
- Electrode Fabrication: We create a “master” copper electrode that represents the negative space of your design.
- Precision Erosion: The electrode is submerged in dielectric oil, where it precisely etches the design into the hardened steel mold over several hours.
- Hand Polishing: Once the spark machining is complete, our artisans hand-polish the mold to ensure a flawless strike.
