Medical Device Packaging Design
We are experts in anticipating, identifying and solving your medical device packaging challenges, engineering solutions to suit the end-use of the product. This careful focus complements our pre-validated off-the-shelf packaging solutions.
Our strategic approach to packaging development
Every medical device has unique packaging requirements throughout its lifecycle. Our approach ensures that your packaging solution is optimized for protection, efficiency, and ease of use.
Our development process includes:
- Understanding your product needs and regulatory requirements
- Exploring and agreeing on creative design solutions
- In-house blister production for rapid development
- Sample packaging for evaluation and testing
- Qualification and validation of the final packaging design
To maximize efficiency, we align custom designs with our pre-validated sealing seam shapes, allowing for rapid project completion while still enabling an individualized packaging solution.
Usability is at the forefront of every design—we ensure that packaging is intuitive, easy to open even with gloves, and tailored to clinical workflows.
Designing for clinical workflows
During the design phase we consider the end-use of the solution, taking care to optimized designs to support medical professionals in their critical work.
Small-Format Packaging for Space Efficiency
Sterile-packed products can consume significant storage space in warehouses and OR setups, especially small products like screws.
Our smallest blister packaging formats minimize volume consumption while ensuring the highest standards of sterility and cleanliness. This provides a compact, practical solution for space-constrained hospital environments without compromising reliability.
No-Touch Sterile Access
Maintaining sterility during product removal is a critical challenge. Conventional packaging designs can expose the product to contamination, by requiring direct touching or the placement of the item on a surface.
We offer an innovative solution that enables direct, instrument-based removal from the packaging. For example, a screwdriver can directly engage with the sterile product inside the blister, ensuring aseptic handling without additional transfer steps.
Injection-molded tubes can also be used to minimize contamination risk. While these are ideal for some products, they require a higher production volume and can be costly to customize. Our IP-protected blister design offers a cost-efficient alternative that can be produced for both low and high volumes.
Custom and off-the-shelf packaging solutions
Our packaging engineering team works closely with clients to develop tailor-made solutions while also providing cost-effective, pre-validated packaging options.
We help find the right balance between customized and off-the-shelf components, ensuring that each project benefits from the most efficient and cost-effective approach.
Packaging for different production volumes
We offer flexible packaging processes that accommodate both low- and high-volume production:
- Manual Packaging – Ideal for small batch sizes, as low as two parts per lot.
- Fully Automated FFS (Form-Fill-Seal) Blister Packaging – A high-volume solution where the blister is formed, filled, sealed, printed, and cut in a single process.
By adapting the packaging process to the needs of each project, we help optimize production costs while maintaining efficiency and compliance.