How to Make Acrylic Medals: A Complete DIY Guide

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Custom awards don't just have to be heavy metal medals that cost a lot to make anymore. Acrylic medals are now one of the most popular choices for races, tournaments, school events, esports, and branded promotions. They look modern, are easy to change, and most importantly for makers and small business owners, they make money and can grow.

This guide will show you step by step how to make acrylic medals using laser cutting and engraving. The process is easy for beginners to follow, can be done again and again, and is perfect for anyone who sells custom goods online or in person.

1. Why Acrylic Medals Are So Popular Today

It's important to know why acrylic medals are popular before you start the process.

Compared to traditional metal awards, acrylic medals offer:

• Lower production cost
• More design freedom (shapes, layers, colors)
• Fast turnaround time
• Lightweight and durable structure
• Easy personalization (names, dates, rankings, logos)

That’s why many event organizers now prefer custom acrylic medals for:

• Running races and marathons
• Cycling and triathlon events
• School competitions
• Corporate team-building events
• Esports and gaming tournaments

Acrylic medals are great for small businesses because they let makers get repeat orders and make a lot of them at once.

2. What Are Acrylic Medals?

An acrylic medal is an award made primarily from cast acrylic sheets instead of metal. Designs are usually laser cut and laser engraved, then layered or assembled with glue and hardware.

Common features include:

• Clear, frosted, or colored acrylic
• Engraved text and patterns
• Multi-layer designs for depth
• Attached ribbons or lanyards

Because acrylic is easy to laser process, you can create diy medal ideas that would be very difficult or expensive with metal.

3. Tools & Materials You’ll Need

Preparation Checklist

To make professional-looking acrylic medals, prepare the following:

1. 3mm cast acrylic sheets
   • Black acrylic
   • Red acrylic
   • Clear acrylic
2. OneLaser XRF
   • Ideal for high-detail engraving and clean cutting
3. LightBurn software
   • Industry-standard laser software
4. Racing medal file
   
5. Assembly materials
   • Acrylic glue
   • Medal ribbon
   • Screws (for layered assembly)

4. Step-by-Step: How to Make Acrylic Medals

Step 1: Place the Acrylic Sheets on the Laser Bed

Start by placing your acrylic sheets onto the working bed of the OneLaser XRF.

Tips for best results:

• Keep protective masking on acrylic to reduce smoke marks
• Use magnets or clamps if needed to keep sheets flat
• Arrange black, red, and clear acrylic efficiently to reduce waste

Proper placement ensures clean cuts and consistent results, especially important for batch production.

Step 2: Import the Medal Design into LightBurn

Open LightBurn software and import your racing medal file.

Before running the job:

• Separate engraving layers from cutting layers
• Assign different colors to engraving vs cutting paths
• Double-check scaling (medal diameter and hole alignment)

This step is crucial for accuracy and repeatability.

Step 3: Set Engraving and Cutting Parameters

Now it’s time to define laser settings for engraving and cutting.

A. Laser Engraving Settings

(For text and patterns on clear cast acrylic)

• Speed: 600
• Max Power: 20
• Min Power: 10

This creates a frosted, high-contrast engraving that lights beautifully and remains easy to read.

B. Laser Cutting Settings

(For medal frames on all acrylic layers)

• Speed: 10
• Max Power: 80
• Min Power: 80

These settings provide:

• Clean edges
• Full cut-through
• Minimal edge melting

Once settings are ready, set up auto focus on the OneLaser XRF to ensure consistent depth and kerf accuracy.

Step 4: Clean and Assemble the Medal Layers

After cutting and engraving, remove the acrylic pieces and peel off any masking.

Assembly Order (Bottom → Top):

1. Red acrylic layer (base color)
2. Clear acrylic layer (engraved text and design)
3. Black acrylic layer (top frame)

Secure layers using:

• Acrylic glue for permanent bonding
• Screws for a premium, mechanical finish

Finally, attach the medal ribbon through the top slot or hole.

5. Acrylic Medal Design Ideas That Sell Well

If you plan to sell acrylic medals, design matters just as much as execution.

Popular acrylic medal design ideas include:

• Racing numbers with layered typography
• Minimalist geometric medals
• Clear acrylic with bold color backing
• Frosted engraving with metallic-look ribbons
• Event logos cut as negative space

Layered acrylic designs often justify higher pricing because they look premium and custom-made.

6. Why Laser Cutting Is Ideal for DIY Acrylic Medals

Using a laser system gives you advantages that manual methods can’t match:

• Precision: Consistent results across hundreds of medals
• Speed: Ideal for bulk event orders
• Customization: Names, dates, categories engraved on demand
• Low material waste: Optimized nesting in LightBurn

For a maker or small business owner, this means higher margins and less rework.

7. Cost Breakdown: Acrylic vs Metal Medals

Many customers ask whether acrylic medals are “cheap.” In reality, they are cost-efficient, not low quality.

This makes diy acrylic medals especially attractive for small events and startups.

8. Scaling Acrylic Medal Production for Business

Once you master the process, acrylic medals are easy to scale.

To grow efficiently:

• Save LightBurn presets for repeat jobs
• Batch cut multiple medals per sheet
• Offer tiered pricing for bulk orders
• Upsell custom engraving (names, rankings, years)

Many small shops turn medal production into a steady seasonal income stream, especially during marathon and school competition seasons.

9. FAQs About Acrylic Medals

What is an acrylic medal?

An acrylic medal is an award made from cast acrylic sheets, laser cut and engraved, often layered for depth and visual impact.

Are acrylic medals cheaper than metal?

Yes. Acrylic medals generally cost less to produce while still offering a premium, modern look.

Can acrylic medals be used for awards?

Absolutely. Acrylic medals are widely used for races, competitions, corporate events, and esports awards.

Are acrylic medals durable?

Yes. Cast acrylic is impact-resistant, lightweight, and holds up well for long-term display or wear.

Final Thoughts: Are Acrylic Medals Worth Making?

If you’re a maker or small business owner, acrylic medals are one of the smartest products you can offer.

They are:

• Easy to produce
• Highly customizable
• Profitable at both small and large scales
• Modern and visually appealing

With the right setup, files, and workflow, learning how to make acrylic medals can open the door to consistent orders and long-term growth.

If you’re already laser cutting acrylic, medals are a natural—and lucrative—next step.