Thermoformed Inlays and Inserts

Ergonomically designed grip handles on plastic thermoformed inlays allow for easy handling, carrying, and removal from containers, as well as reinsertion into the packaging. These finger handles on the sides of the insert enhance its usability when interacting with the surrounding container. The size and placement of these handles should be considered early in the design process, as they can affect both the nesting shape and stacking efficiency of the thermoformed inlay.

The service life of your thermoformed plastic inlay determines its design and material choice. Is the blister packaging intended for single-use or multi-use, and will it be in operation for months or years?

The longer the desired service life and the more frequent the daily use, the higher the quality and mechanical stability of the plastics required. Stabilizing elements such as ribs and reinforcements can further enhance the stability and longevity of the plastic inlays, especially when dealing with high load weights.

Text such as item numbers, logos, material markings, date stamps, ESD markings, or other logos can be important information on your thermoformed insert. These can be directly applied to the inlay. You can specify the placement or leave it to formary's expertise.

Adhering to dimensional tolerances is crucial for ensuring a seamless fit within the surrounding container. Our thermoformed inlays typically comply with ISO 2768c for general applications. However, if tighter tolerances are required, we can also manufacture according to ISO 2768m, depending on the specific application and functional requirements.

Radii define the curvature of the edges of the thermoformed insert, while wall slopes determine the angle of its sidewalls. Thermoformed parts always require a minimum radius and wall slope to ensure smooth demolding. The minimum feasible wall angle depends on the specific design of the inlay. Based on our technical assessment, we determine the optimal values for your application. If you have additional requirements for the wall angles of your plastic inlay, you can specify them easily in our configurator.

To develop a concept for your thermoformed inlay, a detailed analysis of your component is required. A drawing or CAD file of the product is used to determine the exact dimensions.

At formary, data privacy is a top priority. We are happy to sign your non-disclosure agreement in advance.

The weight of your product determines the required material thickness and the reinforcement technique used for the insert. For reusable inlays, the goal is long-term durability, while for single-use inlays, we ensure a stable base with a balanced trade-off between function and cost.

A secure fixation of components within the nest primarily protects your products during use. Undercut techniques can be applied selectively or around the entire insert to ensure a stable hold.

The precise fit of your products is a key requirement for the thermoformed inlay. The nest design is customized based on your specified component positioning to ensure secure placement, stability, and protection.

The nest arrangement of your insert defines how the products are distributed across the surface of the insert. If you plan to place multiple items on the inlay, you can specify your desired arrangement in the configurator.

You can specify the distance between the nests and between the nest and the edge of the thermoformed inlay if you have particular requirements. From a thermoforming perspective, we are bound by certain wall widths, but we can discuss and adjust these with you if necessary.