Thermoform Packaging
Custom thermoformed trays and clamshells for medical device containment, protection, and presentation. Engineered to secure your device precisely through sterilization, shipping, and point-of-use opening.
Thermoform packaging is the workhorse of medical device primary packaging — providing a formed cavity that holds the device securely, maintains sterile barrier integrity, and enables clean, controlled access in sterile environments. At PPR, we supply custom thermoformed trays in PETG, HIPS, and other medical-grade substrates, sized exactly to your device.
Custom Thermoform Trays
Formed plastic trays with custom cavities shaped to your device geometry. Holds devices securely during ETO or gamma sterilization, shipping, and storage. Paired with Tyvek® or film lidding stock.
Clamshell Packaging
Hinged thermoform clamshells for devices requiring tamper-evident, fully enclosed primary packaging. Available in clear materials for complete product visibility.
Blister Packaging
Formed blister cavities heat-sealed to printed or plain card stock. Common for smaller devices, single-use components, and consumer health products requiring retail-ready presentation.
Tray + Tyvek® Lid Systems
Thermoform tray paired with Tyvek® or clear film peel-able lid. The standard configuration for sterile medical device packaging per ISO 11607. Validated seal strength and peel performance.
Material Selection
PETG (blue tint or clear), HIPS (rigidity and cost efficiency), and PVC (clarity, barrier) available. Material selected based on sterilization method, device geometry, and shelf-life requirements.
Tooling Development
Custom tooling engineered for your device. Tooling development coordinated across our manufacturing network to minimize lead time. Tooling owned by customer upon approval.
Standard Process:
Discovery & Requirements
Device specs, sterilization method, use environment, and regulatory pathwayreviewed with your team.
Design + Development
Artwork and specification sheets provided, or new packaging concepts engineeredby our team.
Prototypes + Proposal
Prototypes available for testing and validation. Once approved, pricing and termsare determined.
Validation
IQ/OQ/PQ executed. Accelerated aging and distribution simulation testingcompleted per ISO 11607.
Final Approval + Production
Proofs made to match drawings and specifications. Validated design transferred tofull production.
Materials & Options
- PETG
Polyethylene terephthalate glycol; clear, ETO and gamma compatible - HIPS
High-impact polystyrene; rigid, cost-effective - ISO 11607
Sterile barrier system validation standard - ASTM Testing
Outsourced testing partners; seal strength, visual inspection, gross leak testing etc. - Pad Printing
Custom pad printing available; multicolor availability - Engineering Services
Able to design and develop from physical devices or CAD references
Device Categories We Support
Thermoform Packaging
We engineer thermoform solutions from material selection through tooling and validation — not just supply trays off a shelf. Our manufacturing relationships mean tooling costs and lead times are competitive.
Most companies supply the tray and leave the rest to you. We take the project further — coordinating tooling, supplying the Tyvek® lidding, and supporting seal validation so you're not stitching together multiple vendors to get to a production-ready sterile barrier system. Our sister CMO is also available for all sterile and process qualification services.
