Time to read: 5 min
Image Source: Forbes. Paris Olympics medals.
Since 1904, top Olympians in the Olympic Games have been awarded gold, silver, and bronze medals. As in previous years, the Paris Olympic Games will award medals to Olympic and Paralympic competitors who reach the pinnacle of athletic achievement.
Behind this inspiring vision lies the hard work and complexity involved in creating the medals themselves. At Fictiv, our mission is to simplify sourcing for custom manufacturing projects like this, so we tapped our manufacturing experts to weigh in on the intricate process that would be involved in concepting, designing, sourcing, and manufacturing this year’s Olympic medals—all in service to the incredible heritage of the Games.
The final results: Over 5,000 medals were produced, each 9.2mm thick, and weighing between 450 and 500 grams.
Designing the Olympic Medals
Image Source: Forbes. Close-up of the complex design of this year’s Olympic medals.
Each host city is responsible for the design and manufacture of Olympic medals. This year, the process began when the Olympics Organizing Committee collaborated with artists and designers to brainstorm motifs and themes that embody the Paris Olympics. This culminated in a design competition where artists and designers submitted their proposals and were judged by a panel that included the International Olympic Committee (IOC). The design must adhere to specific guidelines set by the IOC, that required the inclusion of the Olympic motto and the year of the Games.
Assessing Medal Manufacturability
The design would then be shared with manufacturing engineers, who offer design for manufacturability guidance (DFM). Engineers examine the design to ensure it aligns with manufacturing best practices and principles and can be manufactured. Typically this involves an effort to simplify the manufacturing process, reduce production costs, and improve product quality and consistency. But, in the case of Olympic medals, tolerances, repeatability, and aesthetics are critical to the final product, so DFM would prioritize the relevant attributes.
Each medal for the 2024 Paris Olympics contains original iron from the Eiffel Tower. The iron was cut into a hexagon, with puddled iron left in its original color, then placed in the center and embossed with the emblem of the Paris 2024 Games. From a manufacturing standpoint, this precise process requires strict adherence to tight tolerances and aesthetic guidelines.
DFM, in this case, would ensure all of the requirements were included in the design and ready for manufacturing. Reliable, accurate DFM isn’t always easy to find, and finding the right manufacturing partner with in-depth knowledge and expertise in engineering and manufacturing of custom-made items like the medals can be extremely difficult.
Material Sourcing & Sustainability for the Paris Olympic Medals
Increasingly, sustainability is a critical priority in manufacturing and sourcing Olympic medals. This year is no exception. The Paris Olympics medals were made with a strong focus on sustainability, ethical practices, and environmental responsibility. By using recycled materials, ensuring fair trade and conflict-free sourcing, and maintaining transparency in the supply chain, the organizing committee aimed to set a new standard for the responsible production of Olympic medals.
Sourcing complexity is intrinsic to manufacturing in a global economy. Finding responsibly sourced materials from reliable, high-quality manufacturing partners is one of the most significant challenges facing supply chain leaders today.
Prototyping the Olympic Medals
Medals are typically manufactured using casting, which often first requires a prototype with a sand cast or clay mold. This year, the medals are produced by the French National Mint. Likely steps include selecting the appropriate molding material, applying mold release agents to the pattern to prevent sticking, and constructing the mold. The mold material would be packed around the pattern for a single-use mold, such as a sand mold. The curing/setting process would then allow the mold to set around the pattern. The time required for this process can vary depending on the material used. Demolding the final product would remove the cast or break the mold away. Post-cast processing involves finishing steps such as trimming excess material, CNC machining the strap hole, and electroplating or polishing. The Paris Olympic medals likely require all of these steps.
The quality control step is one of the most critical, as this is the process by which any defects or deviations from the design specifications are flagged. Then, continued testing is used to ensure the product meets the required standards and performance criteria.
Olympic Medal Production Testing
Once the Olympic medal casts were ready for testing, test parts would likely have been created to test the validity of the design. A test part is often manufactured using a sand cast, 3D printed, or CNC machined format to test the fit and function of the parts. 3D printing is typically used for rapid prototyping for quick iterations and adjustments, whereas CNC machining is used for prototypes requiring high precision, like this year’s Olympic medals.
Following a close inspection by quality engineers, the medal manufacturer would then provide the prototype to the Olympic Committee in charge of overseeing medal production. After a visual inspection of the medals and X-ray fluorescence spectroscopy (XRF) testing, where X-rays are utilized to confirm the composition meets the requirements using radiation, the Olympic Committee experts would offer final approval.
Olympic Medal Final Production
Once the manufacturer’s quality control team verifies the initial production, the project would then move to production, typically casting, stamping, and CNC machining. Additional advanced techniques for the medals would include engraving and embossing. Each medal would then be carefully crafted to meet high-quality durability and aesthetic standards. The final finishing steps often involve electroplating, polishing, cleaning, or a combination of these steps.
Assembly & Shipping
After securing final inspection and quality control, including inspection to ensure the medals meet all the quality standards, the final assembly might involve further polishing. Next, ribbons are often produced using the colors and branding of the specific Olympic Games.
Finally, the manufacturer would carefully package, label, and ship the final products to the Olympic Committee. This step involves everything from customs to documentation and logistics, to ensuring security clearance.
Vision Meets Design & Manufacturing
The design and manufacture of the Paris Olympics medals blend artistic vision, technical expertise, and a deep respect for the Olympic Games’ tradition and values. The manufacturing process is incredibly complex, but the rewards are clear: Seeing the Olympians claim their place on the podium, medal in hand.
Visit our website at www.fictiv.com to learn more about Fictiv and how we help companies simplify sourcing for custom manufacturing.
Sources: Olympics.com, How It’s Made, Forbes