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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
medical blister packaging

Lightweight packaging designed around your device

Custom thermoformed medical blisters provide protection and presentation for smaller, lightweight medical devices and components that do not require the more substantial structure of a medical tray. Each blister is developed around product geometry, material behavior, sealing requirements, and intended use.

Medical blister packaging can incorporate:

  • Custom-formed cavities designed around product geometry
  • Seal-flange geometry for compatible medical lidding systems
  • Formed features for product protection, retention, and access
  • Medical-grade PETG for product visibility
  • Compact, lightweight package configurations

Engineering, tooling, and thermoforming

Integrated medical blister development

Dordan’s integrated approach allows blister geometry, material behavior, tooling, sealing requirements, and manufacturing considerations to be evaluated together throughout development.

medical blister engineering drawing

Blister Design & Engineering

Blister packaging is designed in Siemens NX around product geometry, protection, access, and sealing requirements. Engineering considers cavity geometry, formed features, material distribution, seal-flange design, and manufacturability before tooling is developed.

CNC for producing medical packaging thermoform tooling

Prototyping & Production Tooling

Prototype and production aluminum tooling is CNC-machined in-house using NX CAM. Prototype tooling supports sample development and evaluation of blister geometry, forming characteristics, seal-flange dimensions, and manufacturability.

Medical blister thermoforming

Cleanroom Thermoforming

Medical blisters are thermoformed in Dordan’s 3,200 sq. ft. ISO Class 8 cleanroom under an ISO 13485:2016-certified quality management system. Controlled manufacturing conditions support consistent forming and material distribution throughout production.

Medical blister thermoforming quality control

Quality Control & Validation

First article inspection and validation verify critical dimensions and package requirements against the project quality plan. Process validation and Cpk capability studies are available based on program requirements.

Cleanroom thermoforming of medical blister packaging

Dordan manufactures medical blister packaging in its 3,200 sq. ft. hard-wall ISO Class 8 cleanroom, providing a controlled manufacturing environment for medical packaging applications. Temperature, humidity, and airborne particulate levels are controlled and monitored to support consistent thermoforming conditions throughout production.

Medical blister programs are manufactured under Dordan’s ISO 13485:2016-certified quality management system, with quality requirements established for each application. First article inspection and validation can be used to verify critical dimensions and package requirements, with project-specific dimensional and tolerance requirements incorporated into the quality plan as needed.

For lidded medical blisters, consistent material distribution and seal-flange geometry are particularly important to support a repeatable sealing surface and finished package integrity. Process validation and Cpk capability studies are also available based on project requirements.

cleanroom thermoforming of medical blister packaging

Start your medical blister packaging project

Dordan provides custom medical blister design, tooling, and thermoforming in an ISO Class 8 cleanroom, supported by ISO 13485-certified quality management.

Request a Quote Call (815) 334-0087