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Calcimator

Blister Pack Design Calculator

Cavity dimensions, card size, and formability for blister packs.

Inputs

Results

Card Width (in)

3.27

Card Height (in)

5.77

Card Area (sq in)18.9
Draw Ratio0.5
Formable? (1=Yes)1
Material Cost/Unit ($)$0.09
Top Opening Length (in)3.27
How to Use This Calculator
  1. Enter product dimensions (length, width, height in mm) and the number of cavities per card.
  2. Enter thermoform material thickness (mm) and card stock weight (g/m2).
  3. Read total blister pack dimensions, cavity layout, and material area (cm2).
  4. Review forming depth-to-width ratio — ratios above 1:1 may cause thinning or tearing.
  5. Use cavity dimensions and material area to quote tooling and material costs.

How the result changes with Product Width (in)

Product Width (in)Card Width (in)Card Height (in)
1.432.75.77
4.365.635.77
7.899.165.77
1112.275.77

What each input means

Product Length (in)
Maximum product length.
Product Width (in)
Maximum product width.
Product Depth (in)
Maximum product height/depth.
Cavities per Card
Number of product cavities per blister card.
Flange Width (in)
Seal flange around each cavity.

What each result means

Card Width (in)
Overall backing card width.
Card Height (in)
Overall card height (including hang hole header).
Card Area (sq in)
Total card material area.
Draw Ratio
Cavity depth / opening. Should be <1.5 for standard PET.
Formable? (1=Yes)
Whether draw ratio is within thermoforming limits.
Material Cost/Unit ($)
Film + card material cost estimate.
Top Opening Length (in)
Cavity opening with draft angle.

How this is calculated

Worked example, using the default values

  1. Identify Input Parameters
    4 parameters
    Product Length (in) = 3, Product Width (in) = 2, Product Depth (in) = 1, Cavities per Card = 1 = 5 input(s) provided
  2. Calculate Card Width
    Card Width = (topOpeningW + 2 * flangeWidthIn) * cavityCount + flangeWidthIn * (cavityCoun...
    3.27 = 3.27
  3. Calculate Card Height
    Card Height = topOpeningL + 2 * flangeWidthIn + 1.5
    5.77 = 5.77
  4. Calculate Card Area
    Card Area = cardWidthIn * cardHeightIn
    18.9 = 18.9
  5. Calculate Draw Ratio
    Draw Ratio = cavityDIn / min(cavityLIn, cavityWIn)
    0.5 = 0.5

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