Thermoforming

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Thermoforming is a process of producing plastic parts from a flat sheet of plastic under heat and pressure, conforming to the contours of a mold. Blackbourn Solutions provides light gauge, shallow draw thermoforming. At Blackbourn Solutions, our in-house engineers can help in evaluating your needs to see if those needs fit as a custom thermoformed packaging application. From idea conception, design, consultation, engineering, prototyping, production and assembly, our experienced team can help you bring the project from idea to delivery.
Markets served are medical, pharmadeutical, healthcare, safety, electronic, retail, industrial, automotive, manufacturing, construction, agriculture, sporting, cosmetic, and more. Contact us for more information on how we could work with you on your next Thermoforming project.
Specifications and Equipment:PVC, HIPS/PS, PET/RPET/PETGFrom .010” to .060” material thicknessThermoforming Machines250,000 Sq. Ft. Facility

Thermoforming - Retail Freezer Display

Thermoforming

Merchandising Trays

OBJECTIVE: A retail food product needed maximum product visibility for merchandising. Product was in two different sizes and would be merchandised on different shelf dimensions.
SOLUTION: Tray was designed to merchandise two different sized packages. The design allowed for the product to be organized and held upright to maximize visibility and shelf space. Light gauge, shallow draw thermoforming design also included die-cut perforations so it could be changed to fit different shelf dimensions. In addition, an embossed logo was included in the thermoformed front facings so that additional product labeling was unnecessary which saved on labor and label cost. In addition to improved merchandising visibility, the design was engineered to allowed for more product to be displayed which would help ensure that sales were not missed.
PROCESSES: Engineering Design, Tool & Die, Prototype, Thermoforming, Carton and Ship.
SUBSTRATES: 35 mil thickness clear PVC specially formulated for the freezer case

Thermoforming - Medical Packaging

Thermoforming

BackSTop+Disposal Systems

OBJECTIVE: A container to provide safe and quick storage and transport of body fluids and sharps resulting from medical procedures.
SOLUTION: A thermoformed container was designed to hold fluid waste after a cardiac intervention procedure and to prevent leakage until disposal. The design team created a design that also would provide a temporary holder for needles/sharps. The package had a seal-tight lid to make for a quick and safe solution to hold and transport the fluid elimination until disposal. Utilizing our in-house engineering team and in-house tool and die department allowed for a quicker project time from idea conception to shipment of product. 
PROCESSES: Engineering Design, Tool & Die, Prototype, Thermoforming, Carton and Ship.
SUBSTRATES: 25 gauge blue Polystyrene

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Thermoforming

Battery Covers

OBJECTIVE: To protect the battery on the Track Chair from the outdoor elements to extend the life of the battery and the chair.
SOLUTION: A cover was designed that the housed the battery and protected it from the elements. The design needed to bring minimum additional weight to the chair for maximum performance. The thermoformed design created a safe housing for the battery without adding weight to the chair or hindering the use of the chair. The protection of the battery would extend the life of the battery as well as the life of the chair.
PROCESSES: Engineering Design, Tool & Die, Prototype, Thermoforming, Carton and Ship.
SUBSTRATES: Black HIPS 70 gauge

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Injection Molding

Propane Tank Monitor Case

OBJECTIVE: To protect the LTE cellular tank monitor from the elements to ensure continued operation and life of monitor.
SOLUTION: The cover needed to be designed to be durable to protect the LTE Cellular Tank monitor from the elements to ensure continued operation to prevent run-outs that risk frozen pipes and pilot lighting exposure and inefficient afterhours deliveries. The case used the strength of Poly Carbonate combined with UV inhibitor for best performance in the outdoor arena. Design and Prototype was developed with collaboration of in-house engineering team. UV Grey Poly Carbonate cover was produced by injection molding.  
PROCESSES: Engineering Design, Tool & Die, Prototype, Injection Molding, Carton and Ship.
SUBSTRATES: UV Grey Poly Carbonate

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RF Heat Sealing

Safety Data Spiral Flipchart

OBJECTIVE: Manufacturer was looking for a centralized, quick reference for their OSHA standards and emergency procedures. The reference would be posted throughout their warehouses and machinery. 
SOLUTION: The final design to meet the objective was a spiral bound flipchart with 12 clear pockets. Information sheets could be inserted. The staggered tab layout allowed bottom tabs to be visible for finding important information effortlessly. Simple flip-page design quickly conveys important information. Design allowed for easy updating so information can be kept current. Chart could be wall mounted for easy reference. Slim profile takes up minimal space.
PROCESSES: Design, Prototype, RF Heat Sealing, Die-Cut, Carton and Ship.
SUBSTRATES: 35 Gauge Poly, Clear Vinyl, Wire-O-Binding

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Injection Molding

Cellular Base Unit Case

OBJECTIVE: A case/cover was needed for a cellular hub device that monitors properties as well as propane or fuel oil tanks.
SOLUTION: For the hub, the design included multiple components which included the product case and the stand. The materials needed to be durable, but did not need to handle the outdoor elements. This unit is used by Agricultural customers to monitor the building temperature of barns and coops, as well as the tank fueling the heat for the same building. Active diesel tanks and other chemical tanks are also frequently monitored assets on agricultural locations. In addition, seasonal homes are also a common application for the Cellular Base Unit. With the ability to alert to water leaks, furnace burner lock-outs, room temperatures and pool temperatures, this device enables you to provide winter protection for your customer’s home.
PROCESSES: Design, Prototype, Injection Molding, Decoration (Pad Printing), Carton and Ship.
SUBSTRATES: Grey Poly Carbonate

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Thermoforming

Drill Till™ Gardening Tool for Retail

OBJECTIVE: To package, deliver and merchandise the gardening tool for retail. The packaging was designed to best visually highlight the product while also protect the product during handling or shipping.
SOLUTION: Design for this package consisted of a 2-piece clamshell. The clamshell pieces were customized to form-fit the parts of the gardening tool. The design was for maximize retail merchandising, but also to protect sharp pieces during shipping. With applications of in-house engineering support and in-house tool & die department, the project took less than 30 days from design to shipment.
PROCESSES: Engineering Design, Prototype, Thermoform, Die Cut, Carton and Ship.
SUBSTRATES: Clear PVC 25 Gauge

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Thermoforming

iKlear® Cleaning Kit Packaging 

OBJECTIVE: Manufacturer of Dish TV wanted to include cleaning products with their sign up kit as a goodwill/incentive to their clients. Challenge was to keep the cleaning supplies organized and with a retail look. A thermoformed clamshell was formed to fit the contents. The instructions and contents could then be distributed to customers.
SOLUTION: A thermoformed clamshell was designed to form fit the contents. The instructions and contents were designed for maximum merchandising and information of the product. The kits in the clear PVC package could then be consistently distributed to customers.
PROCESSES: Design, Prototype, Thermoform, Die-Cut, Carton and Ship.
SUBSTRATES: Clear PVC

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RF Heat Sealing and Thermoforming

onX Hunt Blister Packaging

OBJECTIVE: Manufacturer needed a package to promote the purchase of their hunting programs.  
SOLUTION: A custom digitally printed blister card was designed to house the program access code and a game license holder. The game license holder was heat sealed vinyl and digitally printed. Both items were sealed together to create a complete package for the retailer to present for sale.
PROCESSES: Design, Prototype, RF Heat Sealing, Decoration (Digital Printing), Thermoforming, Blister Packaging, Carton and Ship.
SUBSTRATES: Suedene Vinyl, Blister Packaging, PVC

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Thermoforming and Injection Molding

BEI Insulator/Shield Covers

OBJECTIVE: The facility needed a cost effective method to reduce the levels of dust in the work environment. Electrified pipes with injection molded white isolators were hung from the ceiling which emit electrons that cause the dust to settle. This resolved the issue of the dust in the work environment, but caused a secondary problem. The dust also settled on the white injection molded isolators themselves which caused a fault shutting the system off. 
SOLUTION: A dust shield was designed. This PVC Cover for BEI Insulator/shield was thermoformed and die cut. The shield was a clear case that locked around each isolator to protect it from the dust. The company’s logo was also thermoformed into the dust shield. The dust removal gave the workers’ healthier surroundings. In addition, down time and frustration of system faults caused by the dust were dramatically reduced.  
PROCESSES: Design, Prototype, Thermoforming, Injection Molding, Die-Cut, Carton and Ship.
SUBSTRATES: Clear PVC, Polyproplyene