08 Oct

[FORMART Tutorial] DIY Blister Card Packaging Without a Mold｜Make Your Own Transparent Figurine Shell

Blister card packaging is a common transparent packaging method for collectible figurines, models, handmade products, and small items. Traditional blister packaging usually requires custom molds and higher minimum quantities, which can be difficult for small creators. With the FORMART Smart Vacuum Former, you can use PET sheets to create custom blister card packaging for prototyping, display, and small-batch packaging.

🛠 Tools & Materials

📌 Tools Required

FORMART Smart Vacuum Forming Machine
Laser cutter (such as FLUX Beambox or other CO₂ laser models)
8mm hole punch
8mm locking pins (or PET-specific UV adhesive)

🧵 Materials

3mm wooden board
PET sheet (recommended thickness: 0.3–0.5mm)
Air-dry clay

📂 File Download

👉 Click here to download the DXF laser cutting file on Thingiverse

🧩 Step-by-Step Instructions

Step 1: Laser Cut the Backing Plate

Load the DXF file into your laser cutter and cut the 3mm wooden board. After cutting, assemble the backing plate with glue or screws, and check whether the size and hanging hole position match your packaging design.

Step 2: Create the Mold Base

Use air-dry clay to fill the bottom of the figurine and shape it with a proper release angle. If the edges are too vertical, the formed PET blister may get stuck, so it is better to smooth the bottom and corners before forming.

Step 3: Vacuum Form the PET Blister

Place the PET sheet on FORMART, heat it, and vacuum form it over the clay mold. After forming, let the PET blister cool completely, then trim it along the required outline.

Step 4: Fold & Assemble

Fold the formed blister in half, punch an 8mm hole, and secure it with an 8mm locking pin. If you do not have a hole punch, PET-specific UV adhesive can also be used for sealing.

🎥 Tutorial Video: Complete DIY Process

The video below shows the full process, including file preparation, backing plate production, mold base preparation, vacuum forming, and final assembly. It is recommended to watch the video together with the written steps before starting.

💡 Frequently Asked Questions

Q: What thickness of PET should I use?
We recommend 0.3–0.5mm. This thickness range is easier to form and also easier to trim after forming.
Q: What if I do not have a hole punch?
You can use PET-specific UV adhesive to seal the blister instead.
Q: Can I reuse the blister shell?
Yes. If the blister shell is not damaged, it can be cleaned and reused. If the fold line or locking hole is cracked, making a new blister is recommended.

🚀 Conclusion: Create Custom Transparent Packaging in Small Batches

FORMART helps lower the barrier to making blister card packaging. For figurine display, model packaging, handmade products, and small-batch prototyping, it offers a practical way to create custom packaging without outsourcing mold production.

🛒 Ready to Start Your Blister Card Project?

With FORMART, you can create blister packaging for figurines, models, small product displays, and packaging prototypes. Start with the free DXF template and adjust the design according to your product size.

📂 Download DXF File

🛍️ Get FORMART Vacuum Former

Featured
FORMART S Smart Vacuum Former
NT$28,900 Select options This product has multiple variants. The options may be chosen on the product page
FORMART S Smart Vacuum Former
NT$28,900 Select options This product has multiple variants. The options may be chosen on the product page

For more FORMART applications and product information, please visit the MYYARD official website.

【View FORMART Product Page】

Create Custom Blister Packaging Without a Mold | DIY Vacuum Forming with FORMART