Packaging DesignWe take your product from a first brief to a production-ready blister or tray — co-engineered with our forming, sealing and cutting tooling so it runs, seals and validates first time.
Design the pack and the tool together
A pack that looks right on screen still has to form cleanly, seal reliably and cut without whitening. We design your blister or tray and the tooling that makes it in one loop — so what we hand over is proven to run, not just to render.
You bring the product, the market and the constraints; we bring the forming, sealing and cutting know-how. Every feature — draft, radius, wall, seal land, nesting — is drawn with the tool in mind, so the design that leaves us is the design that goes into production.
From brief to tool-ready in five steps
A structured loop, with a clear decision point at each stage — so you always know where the design stands and what happens next.
We start from the product itself — its size, weight, fragility and how it must present and open. Plus the market, sterilisation method, volumes and any regulatory constraints. This is where the pack’s job is defined.
Cavity layout, retention, wall and material candidates — sketched as options and checked against what the tooling can actually form, seal and cut. We flag anything that would drive cost or risk before a line is committed.
The chosen concept becomes full 3D CAD with draft, radii, wall thickness and seal land resolved to our tooling rules. You get a model to review and sign off — and it is already tool-ready geometry, not a concept render.
A prototype tool proves the design in real material — fit, retention, seal and de-nest checked on samples before a hardened tool is cut. Adjustments happen here, cheaply, on the prototype.
The approved design is frozen, documented and released straight to our tooling as one dataset — the same CAD drives the forming, sealing and cutting tools, and feeds validation and traceability.
Every stage has a go / no-go — you approve before we move on, so there are no surprises at tool release.
The whole pack, not just the tray
A blister pack is a system — the formed part, the lidding, the seal and the way it de-nests and presents. We design all of it as one.
Single- or multi-cavity blisters and hinged clamshells, with retention and product presentation designed in.
Rigid trays and inserts — cavity shape, draft and stacking tuned for the product and the line.
Seal land, peel geometry and lidding choice — designed so the seal is strong, even and cleanly openable.
Layout and pitch across the web — maximising yield while keeping every cavity within tool and seal limits.
The rules we design to
One design, the whole solution
The design isn’t the end of the line — it’s the dataset the rest of the solution is built on. Draw it once, tailored to our integrated tooling, and it flows straight through.
The same CAD drives the forming, sealing and cutting tools — combinable into one integrated tool.
Combined tooling →Designed around a real forming film and lidding from our materials range — not a generic spec.
Materials hub →Drawn to seal-integrity and ISO 11607 rules, so the pack is ready for FAT, IQ, OQ and PQ.
Validation →Part references and tool IDs are set at design freeze, so every pack ties back to its record.
Traceability →What you get
Own the design outright, or let us carry it straight into tooling as one project — the CAD is built to move either way.
Tell us about your product and market — we come back with a design approach and a plan.
Existing CAD? Attach PDF, STEP or DXF
Packaging design FAQ
Do I need a finished design to start?+
No. We can start from just the product and a brief — or from an existing sketch or CAD you already have. Wherever you are, we take it to a tool-ready design.
Can you design to a material I already use?+
Yes. We design around your specified material and lidding, or recommend one from our materials range if you’d like guidance — the design is always tuned to a real film, not a generic spec.
Do I own the design?+
Yes — you receive the CAD and drawings and own the design. You can take it elsewhere, or let us carry it straight into tooling as one continuous project.
Does the design come validation-ready?+
It’s drawn to seal-integrity and ISO 11607 packaging rules, so the geometry supports seal, burst and integrity testing. Full FAT / IQ / OQ / PQ of the solution is handled by our validation service.
How long does a design take?+
A straightforward pack can reach tool-ready CAD in a couple of weeks; complex multi-cavity or regulated packs take longer through the prototype and trial stage. We give a timeline after the brief.
The full service, end to end
Design, validation and traceability — three services that hand off cleanly from one to the next, all built on the same integrated solution.
From brief to a tool-ready blister or tray.
You are hereFAT, IQ, OQ & PQ of the whole solution.
Open →Machine, tool, material and user — all logged.
Open →