The creation of the this year’s Medallion was a very interesting process for us. We first came up with the idea of the Medallion’s material and concept after reading article in The Seattle Times in which they referenced a souvenir you could buy at the 1962 World’s Fair made of “durable ZAMAK metal.” This gave us the idea that it was implied at the time to be a new “space-aged” material.

In truth, ZAMAK had been developed as early as 1929 by a factory in New Jersey, and it was used (and is still used today) as an excellent alloy for die cast products, including toys, hardware, and other more mundane purposes. But the term and story behind the souvenir carried with it the appropriate charm we were after.
So, our quest was to find a local foundry that could actually work with ZAMAK to produce a Medallion for us. After a couple of dead-ends we discovered the folks at Morel Industries. As their web banner says, they have been around since the 1890s, so it was clear from the get-go that they were steeped in Seattle’s history. What we didn’t know is what we would find when we met owners Mark and Steve Morel. First of all, they are very friendly and approachable, and it was clear they were passionate about what they do. You get a real “down to earth” feeling while talking with them that is quite unexpected when you consider the massive industrial space they work in, full of smells and sounds of metal being poured, formed, ground, and polished into almost any imaginable shape or size.

Morel Industries was previously known as Ballard Brass & Aluminum, and the family’s connections to metal casting go all the way back to Rudier Foundry in Paris, where the sculptor Rodin cast all his bronzes in France in the late 1800s. Mark and Steve Morel’s grandfather Leon Morel, Sr, who had trained at Rudier, started two foundry’s in Seattle around 1917. One of Leon’s best known works is the bronze bust of Chief Seattle which still stands in Pioneer Square to this day.
The biggest surprise however was that Steve and Mark’s grandfather Leon had also cast several large bronze pieces for the 1962 World’s Fair! Notably, one of the sculptures is the fountain in front of the Intiman Theatre*, by sculptor James FitzGerald. Without realizing the connection, we had used FitzGerald’s work as one of the stops on the opening day Emerald City Search: Scramble Edition. Because of this family connection with the World’s Fair, and out of support for the event, Morel Foundry decided to donate the majority of their services in the creation of the Medallion. In honor of this we would like to informally call the Medallion the “Leon Morel, Sr. Emerald City Search Medallion” in honor of their grandfather.
*Originally the Little Theatre Playhouse — #39 on the map.
In addition to Steve Morel’s casting of the Medallion, Bellingham artist Jim Dixon from American Automata did the original Medallion design. Jim had previously designed the 2010 umbrella-shaped Medallion with a real ruby on top! This year he was asked to work with the space-aged material ZAMAK, and expertly created a design that could be realized in cast-metal. Jim also designed the secret Key that was discovered with the Medallion, and the Art Box that will be opened when the winner of the October Search partners with the April winner to open the box and discover what is inside!
The steps were surprisingly complex: First camera-ready art with clean crisp lines had to be created. Then an engraver had to cut the art into master blanks that were specially machined for the job. Those engraved masters were then used to create the reversed molds which fit together like a clamshell configuration. Several of these sand molds were made, and then molten metal (the raw ZAMAK) was poured into the molds. Finally, the trimming and polishing process involved cutting off the excess metal around the edges, grinding off some of the rough surface that resulted from the sand mold, and then using ceramic beads in a large polishing machine to smooth down the Medallions into their final, polished finish.

We really have appreciated the people who have given their time and skills to bring the Medallion into existence. No-one (except maybe us) knows what the NEXT Medallion-creation adventure will be, but suffice it to say that this one was a fun one!
- Clue Meister