Making Medals For the Upcoming Winter Olympics

Making Medals For the Upcoming Winter Olympics

The jewelry factory “Adamas” invited us to see how it makes medals for Olympic Games “Sochi-2014”. This must be interesting, let’s check it out.

Making Medals For the Upcoming Winter Olympics

Everything starts from a furnace for smelting bronze and silver. By semicontinious casting they smelt a thick leaf. It will be used for making workpieces of medals – square plates which will be heated to 180C and allowed to stand for two hours to remove the internal stress inside the medals. After that they will be slowly cooling.

Making Medals For the Upcoming Winter Olympics

After the cooling the workpiece goes to a lathe where such a washer is cut out. Another lathe provides more precise turning. Upon these operations the diameter of the workpiece becomes 100 mm, thickness – 10 mm.

Making Medals For the Upcoming Winter Olympics

Making Medals For the Upcoming Winter Olympics

Making Medals For the Upcoming Winter Olympics

They look so good after the turning.

Making Medals For the Upcoming Winter Olympics

Now the washer should be secured inside this device for making holes.

Making Medals For the Upcoming Winter Olympics

Making Medals For the Upcoming Winter Olympics

These technological holes will serve to secure the medal on machining attachments.

Making Medals For the Upcoming Winter Olympics

Then the medal is secured on this thing.

Making Medals For the Upcoming Winter Olympics

This process is called high speed milling. The special machining center applies patterns and symbols of the Olympics.

Making Medals For the Upcoming Winter Olympics

The reverse side of the medal.

Making Medals For the Upcoming Winter Olympics

Then the official name of the Olympic Games is engraved in three languages. Besides, they mill a pocket for a ribbon.

Making Medals For the Upcoming Winter Olympics

The obverse side of the bronze medal of Paralympic Games after the milling process.

Making Medals For the Upcoming Winter Olympics

Now they are making four holes for crystals.

Making Medals For the Upcoming Winter Olympics

Making Medals For the Upcoming Winter Olympics

Maker’s marks are applied on silver and gold medals. Then all the medals are tested and sealed.

Making Medals For the Upcoming Winter Olympics

Surface-grinding machine is used to polish both sides of the medals.

Making Medals For the Upcoming Winter Olympics

Making Medals For the Upcoming Winter Olympics

Ultrasonic bath will help to get rid of all impurities.

Making Medals For the Upcoming Winter Olympics

The next operation is drilling a hole for the pin that will fix the ribbon.

Making Medals For the Upcoming Winter Olympics

Making Medals For the Upcoming Winter Olympics

Rumbling is the next stage, it will provide the medals with a marketable condition.

Making Medals For the Upcoming Winter Olympics

The medal rubs against metal balls of different sizes in the water with a detergent.

Making Medals For the Upcoming Winter Olympics

Making Medals For the Upcoming Winter Olympics

Making Medals For the Upcoming Winter Olympics

Grinding machine helps to prepare the surface of the medal for polishing.

Making Medals For the Upcoming Winter Olympics

Making Medals For the Upcoming Winter Olympics

Making Medals For the Upcoming Winter Olympics

The polishing machine.

Making Medals For the Upcoming Winter Olympics

Making Medals For the Upcoming Winter Olympics

Making Medals For the Upcoming Winter Olympics

And another ultrasonic bath.

Making Medals For the Upcoming Winter Olympics

The last stage is an assembly – the metal part of the medal is connected with crystals.

Making Medals For the Upcoming Winter Olympics

Now they should stay in the fridge at the temperature of -35C – it will help the crystals to be easily inserted into the grooves of the medals.

Making Medals For the Upcoming Winter Olympics

At the normal temperature the crystals will enlarge and stand tight in the medal.

Making Medals For the Upcoming Winter Olympics

Packing.

Making Medals For the Upcoming Winter Olympics

What about the crystals? They are cut out of such sheet of polycarbonate (it looks like glass but has superior properties).

Making Medals For the Upcoming Winter Olympics

It is as thick as a medal is.

Making Medals For the Upcoming Winter Olympics

They use special cutter with protective coating for the crystals.

Making Medals For the Upcoming Winter Olympics

They cut out crystals of different sizes.

Making Medals For the Upcoming Winter Olympics

The polycarbonate is cooled by a jet of compressed air to decrease friction and deformation of the

Making Medals For the Upcoming Winter Olympics

Such a sheet they get as a result.

Making Medals For the Upcoming Winter Olympics

And these are ready crystals.

Making Medals For the Upcoming Winter Olympics

Patterns will be applied to the crystals with a laser.

Making Medals For the Upcoming Winter Olympics

It happens behind this door.

Making Medals For the Upcoming Winter Olympics

This equipment costs some dozens of euros and it’s usd for processing crystals.

Making Medals For the Upcoming Winter Olympics

The program helps to choose a proper pattern.

Making Medals For the Upcoming Winter Olympics

The laser applies the pattern right in the centre of the crystal.

Making Medals For the Upcoming Winter Olympics

This orange thing is used to remove combustion products of the laser engraving.

Making Medals For the Upcoming Winter Olympics

And here’s what they get.

Making Medals For the Upcoming Winter Olympics

Here the medals were designed.

Making Medals For the Upcoming Winter Olympics

Such pins help to fix ribbons in the medals.

Making Medals For the Upcoming Winter Olympics

These ones are mounted manually on the obverse side of a Paralympic medal to form symbols SOCHI2014 in the language of Braille.

Making Medals For the Upcoming Winter Olympics

The very place where the medal design is created.

Making Medals For the Upcoming Winter Olympics

Making Medals For the Upcoming Winter Olympics

“The capital jewelry factory. Just an ordinary factory. For twenty years already”.

Making Medals For the Upcoming Winter Olympics

Making Medals For the Upcoming Winter Olympics

Gold medal which is actually silver inside! It is six grams heavier than an ordinary silver medal.

Making Medals For the Upcoming Winter Olympics

Making Medals For the Upcoming Winter Olympics

Silver medal.

Making Medals For the Upcoming Winter Olympics

Bronze medal.

Making Medals For the Upcoming Winter Olympics

Paralympic medals a bit heavier.

Making Medals For the Upcoming Winter Olympics

Making Medals For the Upcoming Winter Olympics

Silver Paralympic medal.

Making Medals For the Upcoming Winter Olympics

This bronze medal approximately weighs 585 grams.

Making Medals For the Upcoming Winter Olympics

They will make 1300 medals in general. It normally takes twenty hours to make one. Such pettern is applied on a medal.

Making Medals For the Upcoming Winter Olympics

Various Russian patterns.

Making Medals For the Upcoming Winter Olympics

Even patterns of Dagestanian masters are present.

Making Medals For the Upcoming Winter Olympics

These variants of medals remained only on sketches.

Making Medals For the Upcoming Winter Olympics

Medals of previous Olympic Games (Salt Lake City, Turin, Vancouver).

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