Orcon Industries has been designing packaging solutions for over 40 years. Serving a wide range of industries from automotive to aerospace, we’ve built a reputation for packaging that protects products and supports our customers’ performance. One area where packaging truly matters is in the medical field.
Medical devices are often delicate, expensive, and made with highly sensitive materials. Whether it’s components used in surgical equipment, diagnostic tools, or custom-fit prosthetics, none of these items can afford to be mishandled or contaminated. Proper packaging plays a major role in making sure these items arrive safely without damage, exposure, or contamination.
That’s where thermoformed packaging comes in. With its form-fit design and clean layout, this type of packaging offers a strong and reliable solution for protecting medical devices from manufacturing to end-use. It gives manufacturers peace of mind, while making things easier for medical professionals and their patients. Here’s a simple breakdown of how thermoformed packaging works and why it’s such a smart option for the medical industry.
What Is Thermoformed Packaging?
Thermoformed packaging is created by heating a plastic sheet until it becomes flexible, forming it into a mold, and then trimming it to fit the product. That process results in a package that’s custom-shaped to cradle a particular item, making it ideal for sensitive or fragile materials.
This process opens the door to many design possibilities. Some packages are as simple as a single tray. Others are more complex clamshells with separate compartments to hold everything in place. Either way, the mold can be made to match nearly any shape, which makes thermoformed packaging great for devices with unusual sizes or precise functions.
The final product is lightweight and durable. Whether it’s keeping surgical instruments from shifting during transit or protecting diagnostic components from breaking, thermoformed packaging offers a clean, tailored, and practical solution. Many formats are stackable and easy to store, too. On top of that, they can be made in sterile materials to meet strict healthcare standards.
Key Benefits of Thermoformed Packaging for Medical Devices
There are a few standout reasons thermoformed packaging is a go-to choice for medical device manufacturers and suppliers. It boils down to protection, customization, and hygiene.
1. Protection and Durability
Medical devices can be sensitive to movement, friction, and pressure. A custom-molded thermoformed tray holds each item in place so it doesn’t get jostled during shipping or storage. That’s really important for products with sharp tips, delicate sensors, or small precision-built parts. It also cuts down on returns and replacements caused by damage.
On top of holding items securely, thermoformed packaging is often made with plastics that are strong and resistant to impact. That keeps items safer as they move through warehouses, delivery trucks, or hospital stockrooms.
2. Customization
Thermoformed packaging molds are made to fit the product. There’s no need for guessing or stuffing foam into awkward corners. Whether it’s a small surgical camera attachment or a uniquely shaped implant, the package shape follows the contours of the tool.
That kind of detail makes devices easier to access and place where they belong. There’s less wasted material and better use of space, which matters when storage or sterility is a factor. Custom trays also help reduce mix-ups by separating tools in a way that’s consistent and predictable.
3. Sterilization and Hygiene
Cleanliness is one of the most important parts of medical product handling, and thermoformed packaging helps meet those expectations. It can be produced with materials geared for sterilization, like PETG or medical-grade PVC. These materials work well with gas or gamma sterilization methods, which are commonly used in healthcare.
Many thermoformed trays come with sealed lids or covers that keep the product sealed until use. That creates a sterile barrier for surgical kits and tools, reducing risks linked to handling or exposure in transit.
All in all, thermoformed packaging helps keep medical devices clean, protected, and ready to go—no extra steps, no inventing solutions. It offers built-in hygiene and function by design.
Industry Examples and Applications
Across the medical world, you’ll find thermoformed packaging used for everything from tiny tools to large assemblies. Its flexibility and convenience make it a solid choice across departments and product types.
Here are a few examples:
– Orthopedic implants like knee and hip replacements
– Catheters, stents, and similar vascular tools
– Pre-packaged surgical procedure trays
– Hearing aids and related components
– Testing kits and sample trays used in medical labs
Each of these benefits from the secure fit and easy identification that thermoformed trays allow. A transparent cover makes it easy to see what’s inside without opening the package. In hospitals or emergency rooms where speed matters, that kind of visibility can be a huge help.
In cleanroom environments, the trays can also support sterilized workflows. Some are single-use to further reduce contamination risk. Others can be sterilized and reused briefly for instrument setup or temporary storage. That keeps everything organized and helps streamline time spent during procedures.
How Thermoformed Packaging Gets Medical Devices Ready for Transport
Once a medical device leaves the factory, the main priority is safe arrival. A well-designed thermoformed package gives products the structure and protection needed to get from point A to point B in one piece.
Shipping boxes only provide exterior protection. Inside, movement and shock can cause internal damage. Thermoformed trays help reduce that risk by securing items in place so they can’t shift or scrape during motion.
Think of it like a seatbelt for your medical equipment. It holds everything steady even when shipping conditions aren’t ideal. Whether equipment is being delivered locally in Rochester or shipped across state lines, the packaging ensures it arrives in good shape and ready to be put to work.
That’s especially important when dealing with time-sensitive deliveries to hospitals, surgery centers, or research labs. There’s no room for error, and broken devices can delay care or procedures. Thermoformed inserts keep products safe and reduce the chance of needing a return or rush replacement.
How Orcon Industries Can Help
With decades of experience serving industries that require precise, protective solutions, Orcon Industries has built packaging that stands the test of time—and shipment. Our thermoformed packaging solutions are designed in collaboration with clients to support specific shapes, sterilization needs, and shipping methods.
From early-stage concept development to large-scale manufacturing, we bring together expert engineering and a focus on customer satisfaction. Each thermoformed package is made to match the function and needs of the product inside, while helping businesses around the country stay on budget and on time.
Whether you deal with diagnostics, surgical tools, implants, or kits, our team understands the requirements you face and works side-by-side to solve them.
Protecting Medicine One Package at a Time
Medical-grade packaging works best when it’s built to fit both the product and its use. With its strong yet lightweight construction, sterile support, and flexible design options, thermoformed packaging is an excellent match for the demands of healthcare.
From safe shipping to clean storage, it checks every box without adding complexity. At Orcon Industries, we’re proud to support the companies that keep people healthy by making sure their products are packaged to perform. If your medical devices require extra care during storage or delivery, thermoformed packaging offers the kind of reliability that pays off every step of the way.
If you’re looking for a smarter way to protect and present your medical devices, Orcon Industries offers custom solutions designed to meet your needs. With added precision, safety, and cleanliness, thermoformed packaging helps ensure your products arrive ready to perform. Connect with us to see how the right fit can make a real difference in your packaging process.
