A Guide to the Production Process of Blister Packs

By Hope Chan. Last updated: June 29, 2022

Here’s a bird’s eye view of the steps in this post:

  1. Design
  2. Prototype Creation
  3. Molding + Material Ordering + Carton Ordering
  4. Mass Production – Blister Thermoforming Process
  5. Die Cutting
  6. Quality Check + Packing
  7. Random Recheck + Shipping

Let’s go over them in detail…

Step 1. Design

Specialists draw up prototypes and wait for confirmation from clients.

At this stage, buyers are expected to provide either

1) product size info, or

2) send an actual product

So that we can start the design process. Design service is free of charge and usually takes about a day or two to complete.

Design Demo of Custom Blister Packaging Product

Step 2. Prototype Creation

Make plaster mold prototypes. Send a sample to the client and wait for confirmation.

The custom blister packaging molding process officially starts now.

  • A custom blister pack sample will be produced using plaster mold and then sent to the buyer to check for quality.
  • Once the buyer has confirmed the sample pack, we’ll move on to the next stage.
  • This stage usually takes about 5 days (delivery and transit time excluded)
Plaster mold of custom blister packaging product

Step 3. Molding + Material & Carton Ordering

Copper/Aluminum mold – Get ready for the production process.

Copper Aluminum

Copper Mold

  • Smooth surface + High durability + Moderate cost
  • Long mold production cycle (about 5 days)
  • Unable to produce fine blister products for the lack of details

Aluminum Mold

  • Higher durability + Higher degree of precision
  • Shorter mold production cycle (about 3 days)
  • Able to yield better quality blister products with less scraps

1) Make Copper/Aluminum mold and use them on the mass production process.

2) Manufacturer will start to order the materials needed and the cartons.

Step 4. Mass Production

Start to mass produce thermoformed blister products and to provide updates on progress.


If the blister packaging products require paperboard cards, such as trapped blisters and slide card blisters, then the printing process start at this stage as well.

An worker operating on Die-Cut machine to make blister packaging products.

Step 5. Die Cutting

Cut the thermoformed plastic sheets into a smaller form and make them the desired size and shape.

die cut-before-whole sheet of custom blister product
die cut (after) - custom blister product

Step 6. Quality Check + Packing

Do quality check and remove flawed products. Pack for shipping.

Warehouse-packed custom blister packaging products.

Step 7. Random Recheck + Shipping

Do random rechecks to ensure product quality and then ship the products.

Shipping options

And now you have a rough idea of how blister packaging is made.

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HOW IS BLISTER PACKAGING MADE? A Guide to the Production Process of Blister Packs

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