Electronics are unforgiving. A clamshell that fits poorly or generates static can cost you returns before the customer even opens the box. Here is what goes into a properly engineered custom clamshell for electronics u2014 from someone who has thermoformed millions of them.

Start With the Cavity

The cavity is the heart of the design. It should cradle the device precisely u2014 no rattling, no pressure points. Send us your product and we model the cavity from its actual dimensions; our car electronics clamshells are designed to survive vibration and temperature swings.

Choose Anti-Static Where It Matters

Static-sensitive components need anti-static treated PET or conductive materials. Standard PET generates enough static to damage exposed circuitry in dry climates. If your product is a PCB or bare component, ask for treated sheet.

Seal Type and Re-openability

Electronics often need to be opened by the customer without tools. A trapped or slide blister lets the buyer test the product and return it to the package. Our slide blister designs are favorites for this reason.

Branding Space

Reserve panel space for brand, spec sheet and compliance icons. A printed card insert carries artwork without touching the plastic u2014 which keeps the shell recyclable.

Testing Before Mass Production

We drop-test, fit-test and seal-test prototypes before you approve tooling. You receive physical samples with your actual product inside u2014 not a render. That is how a custom clamshell for electronics gets built right the first time.

Designing Custom Clamshell Packaging for Electronics

A custom clamshell package for electronics must balance cavity fit, static control and customer reopenability — three priorities we test with your actual product before tooling.

Related reading: electrostatic discharge basics.