Blister packaging
Custom blister packaging & blister cards
Formed plastic blisters and printed blister cards for retail pegs and shelves — made by vetted factories, checked by third-party inspectors and delivered duties-paid to your warehouse.
Blister formats we source
- Face-seal blister cards — the blister flange is heat-sealed to the front of a printed card. Lowest cost per unit at volume.
- Full-face seal — the plastic covers the whole card face for a premium, tamper-resistant look.
- Trapped blisters — the blister is held between two cards; no plastic-to-card sealing needed.
- Double blisters — two formed halves around the product for 360° visibility.
- Folding blisters — one-piece formed blisters that fold closed (overlapping with clamshells).
Materials
| Material | Best for | Notes |
|---|---|---|
| PET / RPET | Most retail blisters | Clear, strong, recyclable; our default |
| PVC | Legacy specs | Cheap and easy to seal, but harder to recycle |
| PETG | Sealed blister cards | Seals well to coated cards |
Thickness usually runs 0.3–0.6 mm depending on product weight. For heavier items we confirm with physical samples before production.
What drives blister packaging cost
- Blister size and depth — more plastic and slower forming cycles.
- Material and thickness — PET vs PVC vs PETG, 0.3 vs 0.6 mm.
- Card printing — colors, coating (blister cards need a heat-seal coating), and card stock.
- Mold — a one-time forming-mold cost, reused on reorders.
- Freight and duties — blisters are light but bulky, so shipping per piece matters. We quote landed (DDP).
See real numbers in our clamshell and blister cost guide.
Frequently asked questions
What is blister packaging?
Blister packaging is a pre-formed plastic cavity (the blister) that holds a product against a backing — usually a printed paperboard card that is heat-sealed to the plastic. It is common for retail items that hang on pegs or sit on shelves.
What is the difference between a blister card and a clamshell?
A blister card is a plastic blister heat-sealed to a printed card. A clamshell is a self-contained plastic shell that folds closed around the product. Blister cards are usually cheaper per unit at high volume; clamshells need no sealing equipment and are more tamper-resistant.
Do I need a heat-sealing machine for blister cards?
For face-seal and full-face blister cards, yes — the card and blister are sealed together. If you don't have sealing equipment, a trapped blister or a trifold clamshell avoids it.
Can the factory print the blister card too?
Yes. We can source the formed blister and the printed card together so they arrive matched and ready to pack.
What is the minimum order for custom blister packaging?
Custom blisters usually start making sense around 10,000 pieces because of the forming mold. Printed cards can be lower.
Paying too much for packaging?
Send us your current spec and price. We will come back with a factory-direct, landed (DDP) quote — free.