I need to mockup a blister card that I created for a client. They want to see the printed card, and the product placed in position. What’s the best materials to use, and the best way to do this? If you could provide the type of material I’d need to buy, that would be great. Scotch tape is “smokey” and probably not a good option. Also, any online tutorials would be GREAT.
Also, some of these products can be a bit bulky… and I need to ship the mockup to the client … so the final mockup needs to be rather sturdy.
Any print/packaging designers, or crafty people, please help!
The only way to make a blister card look real is to make a real blister – thermoformed PETG or vinyl and attach it to the printed back card with clear adhesive. We do a lot of them for clients – a bit expensive but they are indistinguishable from production.
Look at a few more and see if you understand the process… and then proceed vis-a-vis the video. You will need a “form” that is representative of your package blister to draw that plastic over; it can be wood, plaster, etc.
PETG would work, polycarbonate would work, in a pinch, and on the cheap (and it will show), you could probably get away with clear polystyrene, which you might be able to find at a large hobby shop.
TAP Plastics carries a lot of thin gauge sheet stock suitable for low volume thermoforming … google TAP Plastics
All above is correct. You need to have the thermoform mocked up. You are going to have to mock this up anyway before production anyway. Why don’t you have the supplier do it for you? You have to pay for a proto tool. That however is a one time cost.
Don’t have time to get a supplier to do it. and little time to order things. I’ll have the products in a day or so, and then have to mail them back to my friend (mocked up, so he can “sell the concept”).
So, I got some good direction on what plastic sheets to use (PETG, polycarbonate would work, in a pinch, and on the cheap (and it will show) clear polystyrene). How thick should these sheets be?
Any idea where to purchase these sheets locally? Don’t know if I can wait a few days to order it … and would like to avoid shipping. I tried a crafts store (Michaels), but they had nothing. I then tried a hobby store, but they didn’t have any of the above. They did have small “styrene” sheets … which I assume is not the same as polystyrene.
Also tried an art store (Urechts), which had a few sheets as well … but nothing thinner than .60. Assuming I need .20. They also had none of the above plastics … they had PVC.
I also tried a Staples which had these thin plastic covers used for binders (not sure the plastic type) …
Box was crafted and tried…
So, I crafted the box, sealed it, made holes in the top, and tried it out using the plastic sheets from Staples. It seemed that either the plastic was not right, or the suction wasn’t so great (which I don’t think was the problem). The contraption sucked the air, molding the plastic, but it wasn’t a “tight” fit. Rather than really forming against the object, it pulled tight at the center of the object … then eased out on the edges (like the base of a long hill).
Any ideas how to get it to pull tighter? Could it be the plastic?
The suction seems good … as it nearly collapsed the box I was using.
Don’t have time to get a supplier to do it. and little time to order things. I’ll have the products in a day or so, and then have to mail them back to my friend (mocked up, so he can “sell the concept”).
Who is going to be manufacturing this Thermoform? If you want your client to be able to sell this properly you will need a professional mock-up. The amount of time and money you spend trying to rig something together you could have paid someone to do it. This is what comes with being a freelancer, know what your capabilities are and when to look outside.
Another option you may have is to look for a school that has a packaging dept, ID dept, or some sort of prototyping shop. They may have a small thermoformer that they may let you use. Regardless you are either going to have to pay for a tool or make one yourself, which takes time.
I’ve only spent $10 on the cheap plastic that I bought (which I will get reimbursed). I already had the vacuum … made the box from stuff I had laying around. So, cost-wise … no problem on my end. Plus, if I can do this one project great now … then similar products in the future will be already setup. So, from a freelancer’s view, it only helps to get this working now … and saves time in the future.
As for time, I got that. Already setup the box, which was the hard part - Just need the plastic.
From a clients point of view, you are tinkering around with something that may or may not work. I still would not have a tool and if I turn around and say I need 100 of these for client meetings then you are screwed. I personally would rather you spend that time working with a supplier and do it right. Thermoforms can be complicated if you do not know what you are doing. Even if you get your homemade one to work your design still may not be manufacturable.
As far as the issues you are having with your homemade machine… There many things that could be happening. 1) you may not be getting you plastic to the right temp. Make sure it sags with an even gloss. 2) you maybe loosing suction. The 2 boxes and the part need to be air tight. Thermoforming is all about the vacuum. 3) you vacuum may not be proving enough suction for your part.
Aside from my initial comments, to give you a better read on you your prototype we would need to see the part you are trying to form.
On the subject of material, you need to tighten up your math a bit … if you were referring to the “inch” system, .6 is one hundred thousandths over 1/2" [.500"] thick; .2 would be fifty thousandths under 1/4" [.250"].
I think you mean .062 (1/16"), and .020 which is .011" thinner than 1/32" [.031"]; stated; sixty-two thousandths, and twenty-thousandths, respectively.
I mentioned the name of a company in my previous post, they carry several thicknesses of “thin-gauge” polycarbonate, .005", .010", .015", .020", and .030". The sheet size is 24" x 48", so you should get quite a few shots at getting it right.
What you bought at Staples was more than likely acetate. I’m surprised you got it to form at all.
L’ocally’ is New York City. I actually meant “what kind of store” or what “big stores that every city has”.
As for Staples and their “plastic sheets” … yeah, I knew I wasn’t going to get high quality there. It was cheap, down the street, and I wanted to try out my bewly built contraption! It worked a “little bit”, and that made me happy. Just need to perfect it now.
Thanks for the measurement info. This technical stuff is a bit above my head. I think I was referring to 1/16 - being .062. .060 seemed a bit too think for my needs. So, which thickness do you recommend for my needs (as I am following the video above)?
You’re learning a lot, and wasting a bunch of time doing it. You’re not really wasting your time, you’re wasting your clients’ time.
My friend PackageID has years of experience in product packaging, and for him to suggest that "If you want your client to be able to sell this properly you will need a professional mock-up. The amount of time and money you spend trying to rig something together you could have paid someone to do it. This is what comes with being a freelancer, know what your capabilities are and when to look outside" is absolutely valid.
To that end, perhaps you should consider using an “off-the-shelf” package; certainly a lot cheaper, more professional, more “manufacturable” (since you would just buy it), and cost effective overall. If you want to dink around with trying to fake some kind of container, only to find out that you will have to do the work all over when it comes time to “produce” your design, that’s your business.
Your client will, rightfully, assume that if you present him with a mock-up that everything is ready to go. For him to then discover that there are going to be additional design and tooling costs, and probable delays to actually get his product into boxes he will be, well, disappointed; more likely - annoyed; worse - questioning your ability to get him what he needs in a timely manner; worst case - done with your service. And since you do not know who, where, when, or how to acquire your custom blister packaging, how do you propose to explain that to your client when he asks when he can expect to ship product?
polycarbonate, styrene > .015" - .020" would be more than adequate.
Two reference sources you need to know about. MacRae’s Blue Book, and the Thomas Register; they’re both “industrial” bibles for finding “stuff”.
Large hobby shops often carry thin-gauge styrene sheet so guys can mold cockpit canopies for their R/C model aircraft.
Google “thin gauge polystyrene new york city” here’s the first one I got : http://www.plaxall.com/
If nothing else, they may be willing to sell you some stock … personally, I’d ask them what they charge to do a mockup.
One more point. Remember you are making a “works like” prototype. If the exact material is not correct that may be okay (depending on the product you are packing) as long as you are sure the correct material will perform the same.
Canal street plastics, that brings back memories. Glad to hear it is still there. For bike helmet shells we form 0.6-0.8mm PVC sheet and PC sheet, and for the clamshell packs to hold the accessories. PC absorbs moisture so it has to be dried by keeping it warm hot for a while, few hours at that thickness, to prevent cloudiness or bubbles when you heat it up. PVC no such issue.
To get tight corners you have to drill the vaccuum holes into the tightest negative recesses to combat the self sealing effect.
