Blister Packaging in Santa Clara, CA

Blister packaging combines a thermoformed transparent plastic cavity — the blister — with a printed paperboard backing card to create the dominant retail packaging format for consumer electronics, hardware, pharmaceuticals, toys, and health products worldwide. The format provides maximum product visibility through the clear plastic, tamper evidence through the sealed blister-to-card bond, and a large printable surface on the backing card for brand communication and retail compliance information.

Blister Pack Configurations

• Face Seal Blisters: Blister heat-sealed to the front face of the printed card only — the most common retail blister format for standard consumer products
• Full Seal Blisters: Blister sealed around the entire card perimeter — provides maximum tamper evidence and structural integrity for heavier products
• Trapped Blisters: Product trapped between two paperboard cards with the blister cavity formed in one card and the other card forming the back — no exposed plastic edges
• Clamshell Blisters: Fully enclosed hinged plastic shell — product enclosed in transparent plastic on all sides for maximum visibility and security
• Slide Blisters: Printed card slides into a channel in the plastic blister — allows card removal without destroying the blister

Thermoforming Tooling

Each unique blister cavity requires custom thermoforming tooling — an aluminum or steel mold that shapes heated plastic film into the three-dimensional cavity matching the product's dimensions. Tooling lead time is 10–14 days before production begins. Standard tooling amortizes cost over the production run; for very high volumes, steel tooling provides longer tool life than aluminum.