Medical & Life Sciences Thermoforming

Custom Medical Device Packaging

Backed by 30+ years of experience, T.O. Plastics has the expertise and knowledge to design and thermoform the right custom medical device packaging to protect your products.

Our medical packaging solutions offer extensive advantages, including:

  • Light weight
  • Structural stability
  • Nestability
  • Cost efficiency

T.O. customers know they can rely on our products to protect their medical device components throughout all their operations, including processing and transportation.

When it comes to medical device packaging, we have unparalleled experience in design, research and development, production and quality control. We also are capable of reading surface conductivity of the parts we produce.

Our design team is innovative and will assist you with all your medical packaging manufacturing needs.

We excel with packaging tray concepts made from PETG material and polycarbonate. We are committed to assuring a quality product at a fair price, delivered on-time.  Examples of custom medical device packaging that we’ve engineered and manufactured include: 

  • Sterile barrier packaging
  • Long, one-piece catheter trays
  • Storage bins for automated dispensing cabinets
  • Returnable packaging
  • Component shipping trays
  • Diagnostic kit trays
  •  Automation trays

Our expertise extends over the full range of medical fields, such as:

  • Cardiovascular
  • Surgical
  • Orthopedic
  • Patient care
  • Neurosurgery
  • Medical supply
  • Monitoring

T.O.-designed medical device packaging is well-suited for standard sterilization processes. Our products are also easy to handle and can be quickly sealed and pouched at your facility.

Our thermoforming production capabilities include:

  • Certified Class 8 cleanroom
  • ISO 13485:2003 and ISO 9001:2015 - Otsego, MN Facility
  • High speed in-line and cut sheet capabilities
  • Capable of forming polycarbonate parts up to 27" x 84"
  • In-house design, rapid prototyping and machining of production tooling
  • Thin- and thick-gauge thermoforming capabilities
  • HEPA booth/ionized air cleaning
  • 100% inspection
  • Burr-free trim with heated forged dies, line rule dies or matched metal dies
  • Labeling and barcoding
  • Kitting and secondary packaging capabilities

Thanks to our extensive capabilities, T.O. can manufacture volumes ranging from a few hundred to millions of pieces and provide the same level of quality and care for small start-ups as for large multi-national corporations. And we can expand production as your business grows.


Contact us today for the cost-efficient, reliable packaging your medical devices demand .