Behind every consistent thermoformed part there is a controlled process. This article walks through sheet extrusion, heating, forming, trimming and the inspection steps that matter.
Use it as a working checklist when you write your next enquiry.
This category covers a family of products rather than a single item. In practice a buyer defines clamshell 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 hinged single piece designs; snap lock, button lock and RF seal closures; tamper evident tear strips. Materials most often specified are Polypropylene, Polyvinyl Chloride, Polystyrene, Polyethylene Terephthalate, and the choice between them changes stiffness, temperature resistance, chemical behaviour and price.
In the retail and merchandising sector the decision is usually driven by shelf presentation and print quality, with stack strength as a secondary requirement. Typical end uses include promotional packs, counter displays, pegboard blisters.
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 |
|---|---|---|---|
| Recycled PET | 1.35-1.40 g/cm³ | 45-65 MPa | -40°C to 70°C |
| Polystyrene | 1.04-1.06 g/cm³ | 30-50 MPa | -20°C to 70°C |
| Polypropylene | 0.90-0.91 g/cm³ | 25-40 MPa | -10°C to 100°C |
Polypropylene is frequently the default selection here: PP is the lightest mainstream packaging resin and keeps its shape under repeated flexing.
Each step below has its own control points, and skipping one of them is where most defects start.
Critical control points are melt temperature, cooling time and the inspection of the first pieces of every shift. A stable process is documented with a parameter sheet that travels with the tool.
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.
The route below is the one most factories use for this type of part.
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.
Use this checklist when comparing two or three supplier quotations.
Send this list to your supplier with the drawing and you will receive comparable quotations from every factory you contact.
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.
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.
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.
Standard production tolerance follows the relevant ISO or DIN tolerance class for the process; tighter tolerances are possible after machining or grinding, but they add cost. Define the tolerance only on the functional dimensions.
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.
If you are planning a new retail and merchandising 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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