Blister Packaging Design and Manufacturing Process Complete Analysis

Blister packaging is widely used in electronics, toys, hardware, cosmetics, food, and other industries, offering good display effect, strong protection, and high production efficiency.

1. Blister Packaging Types

Common types: blister clamshell (transparent cover, used with paper card), blister tray (product positioning liner), fold-over blister (fully wraps product), tri-fold blister (with hanging hole, suitable for shelf display), flocked blister (velvet liner, premium texture). Different types suit different products and sales scenarios; selection depends on product shape, weight, and display needs.

2. Material Selection

Common materials: PET (eco-friendly, high transparency, good toughness, commonly food-grade), PVC (low cost, good formability, but not eco-friendly, restricted in EU), PS (high hardness, brittle, suitable for trays), PP (heat resistant, microwave-safe, commonly food packaging), PETG (high transparency, high toughness, premium packaging). Material thickness is typically 0.2–1.0mm, selected based on product weight and protection requirements.

3. Design and Production Process

Design essentials: product-to-clamshell gap controlled at 1–3mm (too loose causes movement, too tight makes removal difficult), draft angle 3°–5° (for easy demolding), rib design (improve rigidity), and cutting edge reservation (for easy trimming). Production flow: plastic sheet → heating and softening → vacuum thermoforming → cooling and setting → cutting → punching → quality inspection and packaging. Molds may be plaster (sampling), copper (small-medium batches), or aluminum (high volume, high precision).

4. Quality Inspection Standards

Inspection items: appearance (no obvious scratches, bubbles, color differences, stains), dimensions (key dimension tolerance ±0.5mm), forming quality (no whitening, cracking, uneven thickness), fit (good compatibility with product and paper card), and load test (tray does not collapse under load). Food-contact blister packaging requires food-grade test reports (complying with GB 4806 series standards).