Multi-Cavity PETG Medical Blister Tray for Surgical Instrument Kits
Newly designed custom multi-cavity PETG medical blister tray for surgical instrument kits, ISO 7 cleanroom manufactured, EO/gamma sterilization compatible, secure snap-fit cavity design.
Newly Custom-Designed Project: This multi-cavity PETG medical blister tray is a brand-new custom design we recently completed for a surgical instrument manufacturer client. The client came to us with three pain points: their existing tray couldn’t securely hold all 8 surgical instruments in one kit, instruments shifted during shipping causing surface scratches (5% damage rate), and the old layout wasted 25% of material space. Our engineering team redesigned the cavity layout from scratch, optimized the snap-fit positions, and applied our improved appearance process — resulting in this tray that securely holds every component, reduces shipping damage to under 0.3%, and cuts material cost by 18% per unit.
Product Overview
This custom multi-cavity rigid blister tray is designed for pre-assembled surgical instrument kits, procedure packs, and medical device sets that require multiple components to be organized, fixed, and sterile-barrier packaged in a single tray. Manufactured from medical-grade PETG in our ISO 7 (Class 10000) cleanroom, the tray features 8 individually sized cavities with optimized snap-fit retention, ensuring every instrument stays firmly in place during sterilization, storage, and international shipping — no shifting, no scratching, no damage.
The cavity layout was engineered for maximum space efficiency: every square millimeter of the sheet is utilized, reducing material waste and per-unit cost while maintaining a 0.5mm minimum wall thickness at all high-stress corners. The tray is compatible with Tyvek lids, heat-sealed to form a complete Sterile Barrier System (SBS) that maintains sterility for up to 5 years when stored under recommended conditions.
Key Design Features (Newly Optimized for This Project)
Material & Manufacturing
This tray is manufactured from medical-grade PETG (Eastar 6763 / SK 2008), the industry standard material for rigid medical device packaging. PETG offers excellent clarity, good impact resistance, consistent thermoforming performance, and broad sterilization compatibility. Every batch of raw material comes with full material certification, biocompatibility test reports (ISO 10993), and complete traceability from resin lot to finished tray.
All production is performed in our ISO 7 (Class 10000) cleanroom, using integrated-frame thermoforming machines (no friction particle generation) and tab-free robotic die-cutting handling (no sharp edge protrusions). Finished trays undergo 100% visual inspection for defects, dimensional verification, and particle count monitoring before packaging.
Technical Specifications
| Material | Medical Grade PETG (Eastar 6763 / SK 2008), light blue transparent |
| Overall Dimensions | Customizable per client requirement (this project: 280mm × 180mm × 35mm) |
| Cavity Count | 8 individually sized cavities (customizable for your component set) |
| Sheet Thickness | 0.8mm (0.5mm – 1.5mm available) |
| Minimum Wall Thickness | ≥0.4mm at all corners (≥0.5mm flat areas) |
| Sterilization Compatibility | EO (Ethylene Oxide), Gamma Irradiation, E-beam |
| Compatible Lid Material | Tyvek 1073B / 1059B / 2FS, Hypak, medical grade paper lids |
| Manufacturing Environment | ISO 7 (Class 10000) Cleanroom |
| Dimensional Tolerance | ±0.3mm (cavity), ±0.5mm (overall) |
| Shelf Life (Sterile) | Up to 5 years (with proper lid seal and storage conditions) |
| Certifications | ISO 13485, ISO 10993 Biocompatibility, FDA DMF available |
Typical Applications
This tray design is suitable for a wide range of multi-component medical device and surgical kit packaging, including but not limited to:
- General surgical instrument kits (suture removal sets, dressing change kits, minor surgery packs)
- Orthopedic instrument sets and implant procedure kits
- Interventional and cardiovascular procedure accessory trays
- Dental and oral surgery instrument kits
- Ophthalmic surgical instrument sets
- Endoscopy accessory and disposable component kits
- Any multi-component medical device set requiring organized, secure, sterile packaging
Our Custom Design Capability
This tray is just one example of our custom design capability. If you have a different instrument set, device configuration, or packaging requirement, our engineering team can design a completely custom tray tailored to your exact products. Our design process includes:
- Free design review: We analyze your device dimensions, weight, material, sterilization method, and shipping requirements at no cost.
- 3D design & FEA stress analysis: We provide 3D CAD drawings and simplified stress analysis to optimize cavity layout, wall thickness, and structural integrity before mold cutting.
- Rapid prototyping: We can produce prototype samples within 7-10 days for fit and function testing with your actual devices.
- Mold manufacturing & validation: We build the production mold in-house, run first article inspection (FAI), and provide full validation documentation (IQ/OQ/PQ support).
- Cleanroom mass production: Full-scale production in our ISO 7 cleanroom, with complete batch traceability and quality documentation.
We also provide complete sterile barrier system solutions, including matching Tyvek lids, sterilization pouches, and mounting cards for your full packaging system.
Frequently Asked Questions
Need a Custom Blister Tray Designed for Your Instrument Kit?
Send us your device dimensions or samples today, and our engineering team will provide a free custom design review, FEA stress analysis recommendation, and detailed quotation within 2 business days. We’ve designed over 200 custom medical blister trays for surgical, orthopedic, interventional, and dental device clients worldwide.
