An easy way to make clamshell blister packaging

If you’ve ever wanted to create your own packaging for products like handmade crafts, collectibles, or small figurines, then blister packaging is a practical and professional-looking option. Traditionally, blister packaging relies on expensive moulds and large production runs, making it out of reach for many small businesses, hobbyists, and independent makers.

But there’s a more accessible way.

In a previous guide, we showed you how to make clamshell-style blister packaging using a 3D printer and a vacuum former. However, not everyone has access to a 3D printer. This updated method offers an alternative way to make your own packaging using simpler tools, specifically a laser cutter and a vacuum forming machine.

While we previously presented a packaging type requiring a rather complex 3D printed mould, this time the shape is a bit simpler. Using the DXF files linked below, you can use a laser cutter to cut out the necessary shapes.
If you don’t have a laser cutter, then you can look at the design and make something similar to cut out by hand.

This technique is ideal for small-scale packaging production or custom product presentation, offering a low-cost, low-barrier entry into professional-looking blister packaging.

Watch the full tutorial video below, and download all necessary files to get started with your own vacuum-formed packaging today.

Files

• DXF laser cut files

Machines

• Laser cutter
• MY YARD vacuum former
• 8 mm hole punch

Materials

• 8 mm locking pins or UV adhesive for PET
• Wooden board, 3 mm thick
• PET sheet, 0.3 - 0.5 mm
• Air-dry clay

Instructions