Stamping Parts with Blister + Stamping Structure

Stamping parts with blister + stamping structure integrate stamped metal components with blister-formed plastic (or thin metal) to create lightweight, protective, or ergonomic parts, widely used in packaging, consumer goods, and medical devices. Blister forming (vacuum-forming thin plastic sheets into 3D shapes) excels at creating complex, lightweight enclosures, while stamping produces strong, precise metal components (e.g., clips, brackets) that add structural support or functionality. Combining the two creates parts that leverage the strengths of both technologies.

The structure typically involves two components: a blister-formed shell (e.g., a plastic tray for medical devices) and stamped metal features (e.g., locking clips, hinges) attached to the shell. For example, a medical device packaging tray uses a blister-formed plastic base (transparent for visibility) with stamped stainless steel locking clips— the clips are stamped with precision notches, then heat-staked or glued to the blister shell to secure the device during shipping. Another application is consumer goods: a portable speaker’s outer casing uses a blister-formed aluminum shell (lightweight, heat-dissipating) with stamped steel mounting brackets (for attaching internal components), creating a durable yet lightweight structure.

Key benefits include design flexibility and cost-effectiveness: blister forming allows for custom shapes and textures (e.g., anti-slip surfaces), while stamping provides high-strength features at low cost for high-volume production. Additionally, the combination reduces weight— a blister-stamped electronics enclosure is 20-30% lighter than a fully stamped metal enclosure, making it ideal for portable devices. A packaging manufacturer reported that blister-stamped medical trays had a 98% product protection rate during shipping, compared to 90% for fully plastic trays, as the stamped metal clips prevented accidental opening. For parts requiring a balance of lightweight design, protection, and structural support, blister + stamping structures offer unique advantages.

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