Tray

Thermoformed Blister Tray Systems

Rigid Protection Meets Surgical Precision


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Eagle Medical’s thermoformed blister tray systems provide rugged, precisely engineered packaging for complex, high-risk, or delicate medical devices. Designed to optimize clinical workflow while maximizing product protection, our trays are ideal for:

  • Sharp or heavy instruments
  • Devices requiring secure retention and orientation
  • Sequential surgical kits and combination products
  • Products that demand tough, repeatable aseptic presentation

Our in-house engineers collaborate with your team to define the optimal tray geometry, materials, and configuration to meet device, sterilization, and regulatory needs.

Design Expertise That Protects and Performs

Eagle’s cross-functional teams support the entire tray packaging lifecycle, from design and prototyping to validation and production:

  • Custom tray design to match device contours, sharps, and retention needs
  • Surgical presentation optimization for logical instrument access and minimal handling
  • Integrated labeling, kitting, and sterilization services
  • Risk-based material selection for puncture, tear, and crush resistance
  • UV-blocking and light-resistant options for photosensitive components
  • Load-bearing and drop-resistant designs for heavy or multi-part systems

We also support multi-component kits and combination product trays, including mixed-sterilization configurations and hybrid barrier solutions.

Regulatory-Ready and Real-World Tough

All Eagle Medical tray systems are validated to the most rigorous standards for medical packaging, including:

  • ISO 11607-1 and ISO 11607-2 for sterile barrier system design and validation
  • ASTM F1980 for accelerated aging
  • ASTM D4169 for distribution simulation
  • ASTM F1929 and F88 for seal integrity testing (when part of pouch-tray configurations)
  • Full documentation sets (IQ/OQ/PQ) and traceability for global regulatory use

Because we sterilize in-house using both VH₂O₂ and EtO, we ensure your tray solution is functionally and regulatorily compatible from the start.

When Should You Use a Tray?

Trays are a go-to solution when your device or packaging configuration presents unique challenges, including:

  • Sharp components that require containment and separation
  • Products with mass, fragility, or awkward geometry
  • Sequenced presentation for operating room use
  • Combination systems with fluid, vials, or components that must remain isolated
  • Compliance with drop, crush, or shelf-life specifications

Our team will review your device, packaging goals, and regulatory roadmap to determine whether a tray-based solution is the right fit, and we’ll guide you from concept to commercialization.

Everything You Need. All in One Place.

With in-house engineering, tooling partners, sterile assembly, kitting, labeling, VH₂O₂ and EtO sterilization, and validation testing, Eagle Medical offers a streamlined path to launch, without compromising on speed or safety.

Let’s design a tray system that protects your product and elevates your brand.