Forging Medals: The Hidden Engineering of Olympic Glory

This is the season of the Olympics, and it’s raining medals at the Olympic Summer Games in Paris. As the world witnesses top athletes compete for glory, a very few realize that the coveted medal lies beyond its snazzy designs and, as a mark of pride, lies an intriguing process of design and manufacturing. The journey from concept to podium is nothing short of an engineering marvel that showcases an indispensable role machining and manufacturing plays and transcends it’s worth more than in a day today’s life.

The awarded medals act as the basis of benchmarks, and countries as well as keen enthusiasts look forward to the Olympic medal tally, which helps rank countries. Representing the ethos of excellence, respect, and friendship—Olympic values, this year with priorities to sustainability, the medal is uniquely designed in addition to the blend of artistry and engineering.

Designing the Olympic Medals

The process of creating Olympic medals begins with one of the significant steps—design. The host cities work together with the artists and designers, who think of motifs and themes/subjects related to the games. In the context of the Paris Olympics, this involved a design competition in which proposals were decided by a jury with representatives of the International Olympic Committee (IOC).

There are certain rules the design has to meet, one of which is incorporation of the Olympic motto and the year of the games. For the Paris Olympics, with the vision to capture the spirit of the host city and the essence of the Games, included a unique twist: embedding a piece of history into each medal.

Assessing Medal Manufacturability

Once the design is locked, manufacturing engineers come in to provide design for manufacturability (DFM) guidance. Since it is critical to simplify the manufacturing process, reduce costs, and ensure quality & consistency, the engineers review the design to determine the feasibility of actual production as well as to ensure it aligns with best practices.

Again, for the Olympic medals, the issues of tolerance, repeatability, and appearance are important, and therefore, the DFM process set in this regard prioritizes these attributes. For the Paris Olympics, this included the challenge of incorporating original iron from the Eiffel Tower into each medal—a feat requiring precise engineering and manufacturing prowess.

Sourcing with Sustainability in Mind

In line with global trends, the Paris Olympics prioritized sustainability, a critical priority in manufacturing, in medal production. The medals are made with a strong focus on ethical practices and environmental responsibility, adding another layer of complexity to the sourcing process.

Some of the sustainability measures are the use of recycled materials, procurement from fair trade and conflict-free sourcing—from reliable, high-quality manufacturing partners, and maintaining transparency in the supply chain. The aim is to establish the standard of new responsible Olympics medal production, indicating the organizing committee’s attitude to sustainable development.

Bringing the Vision to Life

The prototyping phase typically involves creating sandcast or clay molds. This year, the French National Mint took charge of production, likely employing techniques such as selecting appropriate molding materials, applying release agents, and constructing single-use molds. The process involves multiple steps, from curing and demolding to post-cast processing, including CNC machining and electroplating.

Regarding one of the most critical steps in the medal production—quality control—rigorous measures are implemented throughout the production process. Test parts are created to validate the design, often using 3D printing for rapid prototyping or CNC machining for high-precision requirements. The Olympic Committee oversees production, conducting visual inspections and employing advanced techniques like X-ray fluorescence spectroscopy (XRF) to confirm composition requirements and criteria.

From Production to Podium

Once approved, the medals move to full production. Techniques such as casting, stamping, CNC machining, engraving, and embossing are employed to craft each medal to precise standards. The finishing steps, which are electroplating as well as polishing, are the last processes that give the medals their shiny looks.

The final assembly involves attaching ribbons that reflect the colors and branding of the specific Olympic Games. The medals are then carefully packaged, labeled, and shipped to the Olympic Committee. This step includes managing customs, documentation, and logistics to ensure the medals arrive securely at their destination.

Engineering & Machine Tools’ Omnipresent Role

While the Olympic Games will conclude in ten days, the contributions of machine tools and engineering will continue to be omnipresent in our daily lives. The intricate process of designing and manufacturing Olympic medals exemplifies the importance of engineering and machining, underscoring artistic vision and a deep respect for tradition. These fields are essential not only in creating symbols of global athletic excellence but also in driving technological progress across numerous industries.

HIMTEX: Showcasing Manufacturing Excellence

With more and more focus on athletes performing on the world stage, let us also take our time to look at the innovation & art, sustainable designing, and manufacturing of the emblem of excellence—the Olympic medals. Starting from the devices like the smartphones in our pockets to the vehicles we drive, the impact and influence of precision manufacturing is hard to neglect.

To highlight the critical role of machine tools and engineering in various industries, Hyderabad International Trade Expositions Limited (HITEX) is organizing Hyderabad International Machine Tool & Engineering Expo (HIMTEX). Scheduled for August 16-19, 2024, in Hyderabad, the timely major machine tool show in its 8th edition will be a focal point for the industry, facilitating industry networking, knowledge exchange, and addressing challenges. This event will serve as a cynosure for the industry, offering a platform to witness the diverse and technological advancements in the field of machine tools, engineering, robotics, and automation shaping the growing India’s manufacturing sector.

(Source: www.fictiv.com, www.olympics.com)