Using FORMART to Create Blister Card Packaging for Water Filter | Vacuum Forming × 3D Printing × Laser Cutting Full Workflow

Did you know? If you have a vacuum forming machine, a 3D printer, and a laser cutter at home, you can create professional‐grade blister card packaging—spending under NT$100,000 for all three machines!

In this tutorial, our talented engineer Luke designed this blister card package for water filter cartridges for the InnoVEX exhibition. It features a simple snap-fit design and precise laser‐cut structure, enabling DIY blister card packaging to be produced in small batches.

What Is a Blister Card and Why DIY?

A blister card is a type of packaging that combines a transparent plastic blister with a paper card, widely used for tools, accessories, electronic components, and small product displays.

• Great display: Clearly showcases product appearance
• Easy to hang: Convenient for retail shelf display
• Dust and moisture protection: Extends product shelf life
• Simple process: Quickly made using vacuum forming

With FORMART S vacuum forming machine, you can produce high‐quality blisters at low cost, enabling small‐batch, varied production.

Preparation: Files, Materials, and Tools

🔗 Download STL File

• Download STL model for blister card

🧴 Materials

• PET 0.3 mm plastic sheet
• SpiderMaker EX-450HR resin

🛠️ Equipment

• FORMART S vacuum forming machine
• Phrozen Transform 3D printer
• FLUX Beamo laser cutter

 Step‐by‐Step Production Process

🔨 Step 1: Print the Mold

Use the Phrozen Transform to 3D print the physical mold from the STL model.

🔨 Step 2: Vacuum Forming the Blister

Place the mold into the FORMART S, set the appropriate temperature and vacuum pressure, and form the complete blister.

🔨 Step 3: Create Alignment Jig

Use an FDM 3D printer to make an alignment jig, ensuring the blister does not shift during laser cutting.

🔨 Step 4: Laser Cutting the Blister

Use the FLUX Beamo to laser cut, trimming the blister edges precisely according to the design.

💡 Mold Design Tips

• Chamfer the mold edges to make demolding easier and avoid scratching the blister.
• Add vents at the bottom of the mold to improve vacuum adhesion.
• Adjust the snap‐fit structure to match the thickness of the paper card for accurate and stable results.

❓ FAQ

Q: Is the PET sheet food‐safe?
A: The PET used here is food‐grade, made from 80% recycled bottles. It offers high transparency and impact resistance, making it ideal for chocolate molds or other applications requiring clarity and strength.

Q: Is this suitable for beginners?
A: Absolutely! FORMART S comes with video tutorials and STL files, allowing you to go from modeling to cutting in a home workshop.

Q: Will the formed blister deform easily?
A: As long as the mold is designed properly and you use the right thickness (e.g., 0.3 mm PET), the finished blister is as stable as commercial products.

✨ Extended Applications

• Electronic accessory packaging
• Tool set blister cards
• Small toy packaging
• Exhibition sample displays

📩 Want your product to have professional‐looking packaging? Experience the power of FORMART S vacuum forming machine today and start creating your own custom packaging!

👉 Visit the FORMART S official product page to learn more about features and case studies.

📞 Contact us: service@myyardtech.com