A person in a lab coat and blue gloves examines a transparent container under a bright lamp in a medical laboratory setting. The container appears to hold some form of specimen or sample related to healthcare research.

Thermoformed Medical Device Packaging

Medical Device Packaging for Healthcare

Brentwood is a premier supplier of custom thermoformed medical device packaging. Our design staff meticulously designs each detail of the packaging to ensure the device is secure, but still easy to remove from the packaging when it is time for use.

A custom thermoformed tray for medical devices, made by Brentwood Industries.

Medical Device Tray

Tray with Insert

Medical Device Tray with Insert

Blue PETG Tub with PTEG Foam Device Insert

Clear Clamshell for Medical Device

Orthopedic Implant Tray

Medical Device Tray

Services

Part Design

Process Design

Tooling

Quality Planning

Part Design

Brentwood collaborates with each customer to develop the right packaging solution for your unique needs. Our team of skilled designers, tool engineers, and CNC programmers works to ensure that the custom-tailored design meets your requirements for performance, functionality, and product protection.

Process Design

Our internal project management team is well-practiced at working with complex timelines and deadlines designed to get your product to market. We ensure the process flows smoothly from the first tooling order through final delivery. After that, project management works directly with our customer service team to make sure you can easily reorder parts.

Tooling

After collaborating with you throughout the design, prototyping, and approval processes, we utilize the knowledge gained to develop high-quality production tooling. All production tooling is produced using top quality materials and is precision machined to the highest tolerances. Post-production, all tools are carefully stored and maintained for future runs.

Quality Planning

Brentwood’s quality management system is integrated into every step of the development process, guaranteeing consistent products that meet or exceed your expectations. With the end user in mind, we continue to innovate in research and design, providing efficient packaging that simplifies handling and reduces material use.

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Materials

Choosing the appropriate plastic material for your application is an essential step in developing a successful finished part. Each material has its own characteristics, properties, and strengths. Therefore, many factors can influence material selection, ranging from performance to appearance to cost. By working with you to understand the parameters of your project, we can help you choose the best, most cost-effective method to achieve your goals and meet regulations.

Close-up of multiple spools of filament in various colors, including gray, orange, green, and red. The spools are stacked and arranged randomly on a table.

PETG

One of the most widely used materials for medical thermoformed tray packaging is PETG (glycol-modified polyethylene terephthalate). This transparent material allows for easy visibility of the packaged medical device, a crucial factor in applications where quick identification is necessary. PETG provides a balance of toughness and resistance that helps protect delicate medical devices during transportation and handling.

A close-up image of several overlapping, white rectangular sheets of paper fanned out against a dark background.

HIPS

Another commonly used material is high-impact polystyrene (HIPS), a versatile and cost-effective option. Though it lacks transparency, HIPS offers significant advantages in medical device packaging, including impact resistance that protects medical devices during transportation. It can withstand sterilization methods like ETO, radiation, and gas plasma while maintaining the shape and structural integrity of the packaging.

A stack of white foam trays, made from resilient materials, with compartments designed to hold different items.

PETG Foam

PETG foam is another material option that provides a clean and durable alternative to HIPS for opaque product applications. It consists of PETG outer layers for improved sealing and a PETG foam core that enhances impact resistance and density. This multilayer composition improves protection against environmental factors, making PETG foam a reliable choice for demanding medical packaging environments.

A close-up image of a heap of small, translucent white plastic pellets spread on a dark surface.

PP

Polypropylene (PP) is a cost-effective and highly versatile material that features high flexural and impact strength, anti-static properties, and good moisture resistance. It can be produced in different formulations, including clarified versions for enhanced transparency. Polypropylene is compatible with sterilization techniques such as gamma and steam sterilization, making it an ideal choice for healthcare applications where maintaining sterility is essential.

Two transparent sheets, crafted from premium PC, are layered atop a white sheet on a black background.

PC

Polycarbonate (PC) is known for its high-impact strength and stability, making it ideal for packaging that requires higher-temperature sterilization methods like steam. Its superior durability ensures the safety of fragile devices, even under extreme environmental conditions. Despite its higher cost, polycarbonate remains a top choice for applications where performance and safety are non-negotiable, providing unmatched protection against contamination and mechanical stress.

HDPE

High-density polyethylene (HDPE) is a strong and stiff material with good impact and abrasion resistance, making it a reliable choice for medical device packaging. While its milky appearance limits its use in applications requiring transparency, this characteristic makes it a cost-effective option for budget-conscious manufacturers. HDPE’s resistance to chemicals and moisture ensures sterility and protection, making it ideal for securing medical devices throughout their lifecycle.

Tour Our Cleanroom

Brentwood’s cleanroom manufacturing facility offers 30,000 ft² of ISO Class 7 (10,000) certified space, equipped with advanced technology to support both thermoforming and injection molding. With integrated automation—conveyors, stackers, and robotics—we help accelerate your speed to market, manage high-volume production, and maintain exceptional quality standards.

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