Medical blister packaging

Custom thermoformed medical blisters engineered around your device and manufactured in-house for medical packaging applications

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medical blister packaging

Lightweight protection for medical devices

Thermoformed medical blisters provide a compact packaging solution for smaller medical devices and components. Designed for applications where a more substantial medical tray may not be necessary, blister packaging can accommodate device-specific cavities, sealing requirements, and features that support product protection, visibility, and access.

Medical blister packaging can incorporate:

Custom-formed cavities designed around product shape and dimensions
Seal-flange geometry for compatible medical lidding systems
Formed features for product protection, retention, and access
Medical-grade PETG for product visibility

Blister Design & Engineering

Medical blisters are designed in Siemens NX around device geometry, protection, access, and sealing requirements. Engineering considers cavity design, material distribution, seal-flange dimensions, and manufacturability before tooling begins.

CNC for producing medical packaging thermoform tooling

Prototyping & Production Tooling

Prototype and production aluminum tooling is CNC-machined in-house using NX CAM. Prototype tools support sample development, design evaluation, and refinement of blister geometry before production tooling is finalized.

Cleanroom Thermoforming

Medical blisters are manufactured using dedicated thermoforming equipment within Dordan's ISO Class 8 cleanroom. Controlled production conditions support consistent forming for medical packaging applications.

Medical blister thermoforming quality control

Quality Control & Validation

Dordan's quality assurance processes support dimensional accuracy, manufacturing consistency, and compliance with customer specifications. Inspection, process capability studies, and validation activities are tailored to program requirements.

cleanroom, quality, & validation

Medical blister cleanroom manufacturing & quality control

Dordan manufactures medical blister packaging in its 3,200-square-foot, hard-wall ISO Class 8 cleanroom. Temperature, humidity, and airborne particulate levels are controlled and monitored to maintain specified manufacturing conditions throughout production. Documented standard operating procedures support contamination control, including measures to minimize particulate contamination and manage bioburden risks.

Medical blister packaging is manufactured under Dordan's ISO 13485:2016-certified quality management system. First Article Inspection (FAI) verifies critical dimensions and package requirements, while First Article Validation (FAV) evaluates manufacturing consistency and process capability through Cpk studies.

For lidded medical blisters, consistent material distribution and seal-flange dimensions are important to support repeatable sealing surfaces and finished package integrity. Additional process validation, including Installation Qualification (IQ), Operational Qualification (OQ), and Performance Qualification (PQ), is available based on customer and project requirements.

Custom medical blister packaging for your application

From design and prototyping through cleanroom production, Dordan develops custom thermoformed medical blisters tailored to your device and packaging requirements. Share your project details, even if your specifications aren't finalized. Our team will respond the same business day.