Custom Race-Track PETG Medical Blister Tray for Long Shaft Devices
This custom race-track PETG medical blister tray is designed specifically for long shaft medical devices — catheters, guidewires, drainage tubes, or long-shaft surgical instruments. The long oval main cavity follows the natural shape of the device, while a smaller accessory cavity on the right holds matching fittings, connectors, or adapters in the same sterile package.
The light blue tinted PETG material offers excellent clarity for visual inspection, good impact resistance, and broad sterilization compatibility. Multiple square positioning slots around the perimeter flange allow the tray to be paired with a custom mounting card that snaps into place and holds the device flat, preventing coiling, kinking, or movement during shipping. The flat seal flange is designed for heat sealing with Tyvek lid material to form a complete sterile barrier system.
This is a typical solution for interventional catheter and guidewire packaging, where the device has to stay straight and undamaged through sterilization, long-haul shipping, and hospital handling.
Key Features
Specifications
| Material | Medical grade PETG (Eastar 6763 / SK 2008), light blue tint |
| Nominal Wall Thickness | 0.5 mm – 1.0 mm (customized per tooling design) |
| Color | Light blue transparent (clear also available) |
| Cavity Layout | 1 long race-track main cavity + 1 accessory cavity (customizable) |
| Seal Flange Width | 8 – 12 mm, compatible with Tyvek 1073B / 1059B / 2FS |
| Sterilization Methods | EO, Gamma (25–50 kGy with gamma-stabilized grade), E-beam |
| Production Environment | ISO Class 7 (Class 10000) cleanroom, ISO 13485 certified facility |
| Shelf Life | 1 – 5 years (validated per accelerated aging study) |
| Standards Compliance | ISO 11607, ISO 10993, FDA 21 CFR, EU MDR |
Typical Applications
This long cavity blister tray is suitable for packaging long shaft and tubular medical devices, including but not limited to:
- Interventional catheters and guidewires (vascular, cardiovascular, neurovascular)
- Drainage tubes and aspiration catheters
- Long-shaft surgical instruments and laparoscopic accessories
- Endoscopy devices and flexible scope accessories
- Urinary catheters and rectal/enteral tubes
- Other long, flexible, or semi-rigid medical devices requiring flat, kink-free packaging
For flexible devices that need to be held flat and prevented from coiling, we commonly pair the tray with a custom die-cut mounting card in PP or HDPE that snaps into the positioning slots. If your product requires a secondary sterile barrier around the entire tray, we can also supply a matching Tyvek pouch or bag.
We also offer custom medical blister trays in single-cavity, dual-cavity, and multi-cavity configurations for a wide range of medical devices. Every tray is custom-formed to match your specific device geometry, with cavity shape, depth, and retention features designed around your product.
Complete Sterile Barrier System
This blister tray is designed as part of a complete sterile barrier system. Depending on your product’s risk classification and sterile presentation requirements, we can supply the matching components:
- Die-cut Tyvek lids (1073B, 1059B, 2FS) heat-sealed to the tray flange for EO, gamma, or e-beam compatibility
- Die-cut mounting cards (natural or white PP / HDPE) that snap into the positioning slots to hold flexible devices flat
- Sterilization pouches and bags (Tyvek bags, paper-plastic pouches) as a secondary sterile barrier for higher-risk devices
- Custom printing on Tyvek lids or pouches for product identification and traceability
Why Choose Honest Packaging?
Frequently Asked Questions
Q: Can you customize the cavity shape to match my catheter?
Yes. The race-track shape shown is just one example. We design every tray around your actual device dimensions, curvature, and accessory configuration. Send us your device drawings or physical samples and we’ll design the cavity from scratch.
Q: Why do you recommend a mounting card for flexible catheters?
Long, flexible devices like catheters tend to coil, kink, or shift inside a plain cavity during shipping. A die-cut mounting card snaps into the positioning slots and holds the device flat and straight, preventing permanent deformation or kinking that could affect performance.
Q: What material do you recommend for gamma sterilization?
For gamma sterilization at 25 kGy or higher, we recommend gamma-stabilized PETG. Standard PETG can become brittle or crack after gamma exposure. Learn more in our guide to sterilization compatibility testing.
Q: What is the minimum order quantity?
For custom-designed trays, the MOQ is typically 5,000 pieces after mold completion. We also offer smaller prototype runs (50–200 pieces) for fit testing and validation before mass production.
Q: Can you supply the complete packaging system?
Yes. We can supply the matching Tyvek lids, mounting cards, and sterilization pouches as a complete sterile barrier system, so you only need one supplier for your rigid and flexible packaging components.
Need a Custom Tray for Your Long Shaft Device?
Send us your device drawings or physical samples. Our engineering team will design a custom cavity that holds your device flat and secure, with matching lid material, mounting card, and optional secondary pouch for a complete sterile barrier system.
