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Blister Tooling, Tray Tooling & Heat Seal Tooling Solutions

Alepack specializes in custom blister tooling, tray tooling, and heat seal tooling for medical and consumer packaging applications. Our engineering-driven approach combines precision CNC machining, prototyping expertise, and decades of packaging experience to deliver reliable, production-ready tooling solutions.

We support a wide range of thermoformed packaging applications, from medical device packaging to retail blister packs and industrial tray systems.

Custom Tooling Quote

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Machine Information

Machine Details(Required)
Make
Model
Year
Serial Number

Tooling Information

Will This Tooling be Used For Medical/Pharmaceutical Packaging or Consumer Packaging?(Required)
Do You Have Existing Production Packaging Materials For This Tool(Required)
Do You Have Sample Packaging Materials For This Tool(Required)
Do You Have a Solid Model For The Packaging Materials?(Required)

Item

Is this tooling a repeat of an existing tool set?(Required)
If YES, please include Alepack job # in notes. If you checked No please add each individual component needed below.
If you will need additional components along with a full set of tooling please check Yes above, then add additional items below.
Nesting Plates
Quantity
Support Height (For machines that have machine specific or adjustable support heights
Heater/Pressue Die Assembly
Quantity
Will The Heater/Pressure Die be Flat or Contoured to fit Your Tool?
Heater/Pressue Die Assembly
Quantity
Will The Heater/Pressure Die be Flat or Contoured to fit Your Tool?
Eject Plate/Pusher/Slide Assembly
Quantity
Lower Anvil Assembly (Automatic Sealers)
Quantity
Card/Lid Feeder Magazine (Automatic Sealers)
Quantity
Card/Lid Picker Assembly (Automatic Sealers)
Quantity
Blister Tray Feeder Magazine (Automatic Sealers)
Quantity
Blister Tray Picker Assembly (Automatic Sealers)
Quantity
Eject Picker Assembly (Automatic Sealers)
Quantity
Coupon Feed Magazine (Automatic Sealers)
Quantity
Date Code Stamping Assembly
Quantity
RFID Tags
Quantity
Spare Silicone
Quantity
Spare Nesting Pins
Quantity
Spare Fiberglass/PTFE Cloth
Quantity
Length
Width
Thickness (0.005 or 0.010)
Spare Panel Clips (Consumer Packaging Only)
Quantity
Maximum Amount of Packages
If you would like less packages per tray please answer the next three questions.
2. Orientation: length of package pointing
Will this be a rush order?
Please upload samples of all the components in your package along with engineering if available. If no physical samples are available, tooling can be built to drawing specifications but may not be guaranteed. Blister tray & lid samples are usually needed before completion of the tooling. Card formats accepted are: dxf, dwg, stp, iges, All solid works files preceding 2026.
Drop files here or
Accepted file types: jpg, gif, png, pdf, dxf, dwg, stp, igers, Max. file size: 2 GB.

    Custom Blister Tooling

    Alepack designs and manufactures high-precision blister tooling for medical and consumer packaging applications. Our tooling is engineered for accuracy, durability, and consistent sealing performance across high-volume production.

    Our blister tooling capabilities include:

    • Clamshell blisters
    • Blister cards and captured card designs
    • Medical device packaging
      Custom cavity and form-fit designs

    We incorporate advanced design features such as:

    • PTFE hard-coated aluminum components for durability and low maintenance
    • Replaceable silicone seal gaskets for extended tooling life
    • Laser-engraved alignment and identification markings
    • Precision-machined surfaces for consistent forming and sealing

    Our experience includes tooling for a wide range of machine platforms across the medical and commercial packaging industries.

    Custom Tray Tooling

    Alepack provides custom tray tooling solutions for thermoformed packaging trays used in medical, industrial, and commercial applications. Our tray tooling is designed for strength, dimensional accuracy, and repeatable production performance.

    We manufacture tooling for:

    • Medical device trays
    • Shipping and assembly trays
    • Industrial packaging trays
    • Custom thermoformed carrier trays

    Our tray tooling expertise includes complex geometries such as:

    • Drop-flange and flat-flange tray designs
    • Multi-cavity and nested tray layouts
    • Precision fit trays for automated packaging systems

    We engineer tooling to ensure consistent forming, easy part release, and optimized cycle times for production efficiency.

    Heat Seal Tooling

    Alepack specializes in heat seal tooling for blister packaging and tray sealing applications. Our sealing solutions are designed to deliver consistent seal integrity, strong package performance, and repeatable production results.

    We support sealing applications including:

    • Medical packaging seals
    • Tyvek® and medical-grade lid sealing
    • Foil and film sealing applications
    • Cardstock and poly-lid sealing systems

    Our heat seal tooling incorporates precision-machined surfaces and engineered sealing interfaces to ensure:

    • Reliable seal strength and consistency
    • Reduced seal defects and variability
    • Compatibility with a wide range of packaging materials

    Materials Expertise

    Alepack has extensive experience designing tooling for a wide range of packaging materials, including:

    • PET and RPET
    • HIPS
    • HDPE
    • PVC
    • Tyvek®
    • Foil laminates
    • Cardstock
    • Poly films and lids

    We help customers select and optimize materials based on performance, sealing requirements, and product protection needs.