Blister is a thermoformed plastic packaging solution characterized by a transparent, pre-formed plastic cavity or pocket, typically sealed to a backing material, designed to securely contain and display products while providing protection and visibility. This innovative packaging method, which emerged in the mid-20th century, revolutionized retail product presentation and security through its distinctive combination of functionality and visual appeal. The manufacturing process involves heating a thin sheet of plastic material, commonly polyvinyl chloride (PVC), polyethylene terephthalate (PET), or other thermoplastic polymers, and forming it into a specific shape using vacuum or pressure forming techniques. The formed cavity precisely matches the contours of the intended product, creating a custom-fit enclosure that prevents movement and potential damage during transportation and handling. The backing material, which can be paperboard, plastic, or foil, is then heat-sealed or adhesively bonded to the formed plastic cavity, creating a tamper-evident seal. This packaging solution has become particularly prevalent in consumer goods, electronics, pharmaceuticals, and medical devices, where product visibility, protection, and security are paramount concerns. The design considerations for blister packaging extend beyond mere functionality to include sustainability aspects, with increasing focus on recyclable materials and reduced plastic content. The packaging type has garnered recognition in various design competitions, including the A' Design Award's packaging design category, where innovative approaches to blister packaging continue to demonstrate evolution in both form and function. Modern developments in blister packaging technology have introduced advanced features such as child-resistant designs, senior-friendly accessibility options, and enhanced barrier properties for sensitive products, while maintaining the fundamental benefits of product visibility and protection.
packaging design, thermoforming, product protection, retail display, consumer goods, pharmaceutical packaging, plastic forming, sustainable materials
CITATION : "Lucas Reed. 'Blister.' Design+Encyclopedia. https://design-encyclopedia.com/?E=474312 (Accessed on November 17, 2025)"
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