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
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.
Blister & Tray Tooling FAQs
What is thermoform tooling?
Blister tooling refers to the custom molds and tooling components used to manufacture thermoformed blister packaging and trays. Blister tooling is designed to create consistent, high-quality packaging that protects products while meeting production requirements.
What is tray seal tooling?
Tray seal tooling is a specialized type of medical heat seal tooling used to seal coated lids to custom plastic trays for medical packaging. Custom tray tooling ensures accurate dimensions, repeatability, custom fit and a hermetic, sterile barrier seal.
What industries use tray seal tooling?
Ttray tooling is commonly used in the medical device and pharmaceutical industries. This custom tooling solution helps create custom packaging that keeps products sterile and protects them throughout distribution and use.
What is heat seal tooling?
Heat seal tooling is used to apply heat and pressure to seal cards or lids to thermoformed packaging components. Properly designed heat seal tooling helps create strong, reliable seals while maintaining package integrity.
What industries use blister seal tooling?
Blister tooling is commonly used in the packaging of consumer products, automotive and other commercial manufacturing industries. These tooling solutions help create custom packaging that protects products throughout distribution and use. Blister seal tooling typically has faster thruputs than medical tray tooling.
Can you design custom blister tooling for my product?
Yes. Custom blister tooling can be developed from product samples, CAD files, engineering drawings, or prototypes. The tooling is designed to match your product dimensions, packaging requirements, and production goals.
Do you manufacture custom tray tooling?
Yes. Custom tray tooling can be designed and manufactured for a wide variety of applications, including shipping trays, medical trays, assembly trays, retail packaging trays, and reusable material handling trays.
How many packages can I get on my tooling?
There are many factors in calculating how many packages per nest. Size of the seal area on the machine, Total area of seal surface on the nest, size of the nesting pins, silicone durometer and size of the press. We have predetermined calculations for all of these variables. We can usually give you an answer right away.
Do you provide components and parts for my existing blister tooling that is not made by Alepack?
Yes. In most cases we can provide parts and custom components for all types of tooling.
What information is needed for a blister tooling quote?
To provide a quote for blister tooling, we typically require the product dimensions, machine type, packaging specifications, material preferences, annual production volumes, and any available CAD files or engineering drawings.
How long does it take to build blister tooling or tray tooling?
Lead times vary depending on project complexity, tooling design requirements, and production schedules. Most blister tooling and tray tooling projects can be completed within 4 weeks after design approval.
What materials can be used with blister tooling and tray tooling?
Blister tooling and tray tooling can be designed for a variety of thermoforming materials, including PET, RPET, PVC, HIPS, HDPE, foil lids, poly lids, spun polyethylene lids and other specialty plastics. Material selection depends on the application and performance requirements.
Can existing blister tooling be modified?
In many cases, existing blister tooling can be modified to accommodate product updates, dimensional changes, or packaging improvements. Our team can evaluate existing tooling and recommend modification options.
What is the difference between prototype tooling and production tooling?
Prototype tooling is intended for testing, while production tooling is engineered for long-term durability, higher output rates, and maximum manufacturing efficiency.
Why is custom heat seal tooling important?
Custom heat seal tooling helps ensure consistent seal quality, proper package appearance, and reliable package performance. Well-designed heat seal tooling can improve production efficiency and reduce sealing defects.
Can heat seal tooling be designed for existing packaging?
Yes. Heat seal tooling can often be developed for existing blister packs, trays, and packaging formats. We can match samples, drawings, or CAD files to create tooling that meets your current sealing requirements.
Do you provide engineering support for blister tooling, tray tooling, and heat seal tooling projects?
Yes. We provide engineering and design support throughout the tooling process, including design reviews, manufacturability recommendations, material guidance, prototype development, and production tooling optimization.