Plastic blister packaging holds your product in a clear molded bubble sealed to a printed card. Shoppers can see it but can’t easily get into it in the store. Small electronics, tools, cosmetics and toys use it a lot, with a hang hole for peg displays.
Your time is very important to us so we have kept it short.
So here’s how plastic blister packaging works. Clear plastic gets heated and shaped into a pocket that matches your product, the product drops in, and a printed card is sealed across the back, and that’s it, you can see everything but you can’t get at it without tearing the pack, which is exactly why it’s on every peg wall in every hardware and electronics store.
Who orders it from us? Phone accessory brands. Batteries, tools, fishing tackle, cosmetics, little toys, replacement parts. They want to be seen on the hook and they’d rather the item didn’t walk out of the store in somebody’s pocket.
It’s thermoformed. A plastic sheet, usually PVC or PET, gets warmed till it’s soft and pulled over a mold of your product, then it cools and holds that shape, and after trimming and filling it’s heat sealed to a coated paperboard card (that coating is what lets the plastic stick to the card at all).
People forget about the mold. It’s shaped around your product, so if the product size changes later you need a new one, and if you’re about to tweak the item we’d honestly settle that first. Leave a little clearance too. Too tight and the blister can crack at the corners when it seals.
Which style? A full face blister covers the whole front of the card. Partial ones sit over just the product and leave the rest of the card printed, clamshells fold over on a hinge and don’t need a card at all, and slide blisters slip into a card sleeve so they can be opened and closed again. Depends on the product, and on budget.
If it’s really the printed backer you’re after more than a molded bubble, look at our blister card packaging. Want a fully clear box instead? Our clear PVC boxes give a different kind of visibility.
The card does all the selling the bubble can’t.
On the front we’d put brand, product name, a short line on what it does, and some clean space around the blister so it doesn’t feel crowded, then instructions, warnings, contents and the barcode go round the back. Hang hole at the top for the peg (euro slot is a common pick).
Cards print on SBS paperboard with soy-based or water-based inks, and gloss lamination or spot UV adds a shine that sort of matches the plastic. Our team sets up the card dieline and lays out the artwork for free, checks for print issues and sends a digital proof. Related options are in the custom blister packaging range, and our custom packaging guide has the bigger picture.
Both are clear and both are common. PVC forms easily and shows up on most retail blisters, PET gets picked by brands that want to avoid PVC, and we can talk through which fits your product.
Sure, a multi-cavity blister gives each piece its own pocket. Think a set of drill bits, or a lipstick trio.
Standard production is 10 to 12 business days after proof approval, rush if you ask. Minimums are low, often around 50 units depending on the style, and ground shipping is free across the USA.
Similar options include blister packaging for toys, custom action figure blister packs, custom cosmetic blister packaging and slide blister packaging. Browse all of them in custom blister packaging.
