Polystyrene (PS / HIPS) and Polypropylene (PP) are the two most quoted sheet materials for battery and power pack blister packaging in electronics and electrical projects. Both run well on standard thermoforming equipment, but they differ in clarity, toughness and sealing.
The notes below come from day to day production and export work with overseas buyers.
This category covers a family of products rather than a single item. In practice a buyer defines battery and power pack blister packaging by three things: the base resin, the format or dimension, and the performance or certification level it has to meet. Typical options in this category include hanging and shelf formats; tamper evident closures; button cell and cylindrical formats. Materials most often specified are Polypropylene, Polystyrene, Polyvinyl Chloride, Polyethylene Terephthalate, and the choice between them changes stiffness, temperature resistance, chemical behaviour and price.
In the electronics and electrical sector the decision is usually driven by ESD protection and dimensional accuracy, with cleanliness as a secondary requirement. Typical end uses include accessory blisters, device inserts, connector carriers.
These figures are typical for commercial grades and should be confirmed against the supplier's certificate for your specific lot.
| Material | Density | Tensile strength | Service temperature |
|---|---|---|---|
| Polyvinyl Chloride | 1.38-1.45 g/cm³ | 40-55 MPa | -10°C to 60°C |
| Polyethylene Terephthalate | 1.35-1.40 g/cm³ | 50-70 MPa | -40°C to 70°C |
| Recycled PET | 1.35-1.40 g/cm³ | 45-65 MPa | -40°C to 70°C |
Polystyrene is frequently the default selection here: HIPS is the default thermoforming sheet for food packaging and appliance liners.
Polystyrene grades offer rigid and glossy, while Polypropylene brings lowest density among commodity plastics. For electronics and electrical service the difference shows up in impact strength and in the long term behaviour under load.
The practical decision usually comes down to the service environment: temperature, chemical exposure and expected lifetime.
Beyond the base resin, most suppliers offer UV stabilised, food contact, flame retardant, anti-static and recycled content versions of the same product. Ask which additive package is included, because it is often the difference between a part that lasts three years and one that lasts ten.
Processing method drives both cost and performance, so it should be fixed early in the design.
Secondary operations such as printing, welding, machining and assembly are often cheaper to do in the same factory, and they reduce the risk of mismatch between components.
Work through these points in order and most specification mistakes disappear.
Send this list to your supplier with the drawing and you will receive comparable quotations from every factory you contact.
We can provide ISO 9001 quality system documentation, material certificates, RoHS and REACH statements, and where applicable food contact, flame retardancy or drinking water approvals. Tell us your target market and we will match the document set.
Colour is controlled with a masterbatch reference approved by the customer, and every production lot is checked against the approved sample under standard lighting before shipment.
Standard packing is export cartons on fumigation-free pallets, with custom labelling, barcode and retail packing available. We also handle consolidated containers and door to door delivery.
A new tool typically takes 25 to 45 days depending on cavity count and complexity, followed by T1 samples within one week. Existing tools can usually start production within 10 to 15 days of order confirmation.
For standard sizes and colours the minimum is usually one pallet or one production run; for custom tooling the economic minimum depends on the tooling cost amortised over the expected volume. Send us your annual volume and we will calculate the break even point.
If you are planning a new electronics and electrical project, send us your drawing, annual volume and target properties, and we will come back with a material proposal, a tooling plan and a budget quotation.
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