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Medical clamshell packaging

Custom medical clamshells designed to protect, organize, and present medical devices throughout sterile and non-sterile healthcare workflows

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Medical clamshell packaging
Healthcare clamshell packaging

Custom clamshell configurations for medical devices

Medical clamshell packaging provides enclosed protection, secure component retention, and product visibility during handling and distribution. Custom designs incorporate device-specific cavities, hinge configurations, and closure features to accommodate product geometry and intended use.

  • Living hinge and two-piece clamshell configurations
  • Press-fit and friction-fit retention features
  • Visibility for product identification and inspection
  • Compatible with sterile and non-sterile packaging systems

Medical clamshell applications

Applications across medical device packaging

Custom thermoformed clamshells accommodate a range of medical devices, from surgical instruments and diagnostic components to multi-component kits. Package configurations are tailored to device shape and dimensions, handling requirements, and intended use.

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Surgical Devices

Custom clamshells secure surgical instruments and procedural devices during shipping, storage, and point-of-use handling.

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Sterile Barrier Packaging

Medical clamshells can be incorporated into validated sterile barrier packaging systems, including compatible medical pouches, to support device protection and aseptic presentation.

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Diagnostic Devices

Thermoformed clamshells protect diagnostic cartridges, testing components, and sample collection devices during distribution, storage, and handling.

Medical clamshell design, tooling, and cleanroom thermoforming

Dordan provides integrated medical clamshell packaging development and manufacturing, from initial package design through production. Our in-house engineering and tooling capabilities allow clamshell geometry, material selection, hinge performance, retention features, and manufacturability to be evaluated together throughout development.

Medical clamshells are designed in Siemens NX, with prototype and production aluminum tooling CNC-machined in-house using NX CAM. Prototype tooling supports sample development, design evaluation, and refinement before production tooling is finalized.

Production takes place within Dordan's 3,200-square-foot, hard-wall ISO Class 8 cleanroom, where temperature, humidity, and airborne particulate levels are controlled and monitored. Documented operating procedures support contamination control and consistent manufacturing conditions for medical packaging applications.

Dordan's ISO 13485:2016-certified quality management system supports dimensional inspection, manufacturing consistency, and project-specific validation requirements. First Article Inspection (FAI) verifies critical dimensions, while First Article Validation (FAV) evaluates process capability through Cpk studies, as applicable. Additional process validation, including IQ/OQ/PQ, is available based on customer requirements.

Cleanroom manufacturing of medical clamshells

Let's scope your medical clamshell project

Share your device dimensions and protection requirements — even if specs aren't finalized — and a specialist will review your project and follow up same-day. No automated quotes, no pressure.

Request a Quote Call (815) 334-0087