When it comes to custom thermoformed packaging, precision, collaboration, and expertise are key. Whether you’re launching a new product or upgrading your food container design, custom tooling—also known as mold development—is the first step toward high-performance, brand-aligned packaging. At Xiamen Dashan, we simplify this process while ensuring you get exactly what you need.

Here’s a step-by-step guide to how our custom tooling process for blister and thermoformed products works:

Step 1: Design Consultation & Sample Fee

Before any tooling begins, we first confirm your product vision. Please note that for custom products, samples require a fee. The process begins only after we receive the sample fee. This includes:

  • Collecting design details from the client.
    • If you already have technical drawings (CAD or PDF), our engineering team will review and refine them based on your requirements.
    • If you do not have a drawing, you can send us a physical sample, and we will create a professional drawing for your confirmation.
  • You can also provide design ideas or desired features, and we’ll suggest solutions based on thermoforming feasibility, material selection, and manufacturing precision.

Once the scope is clear and the sample fee is paid, we begin drawing and mold development.

Step 2: Prototype Mold & Sample Production

Upon receiving the sample mold fee:

  • We start machining the prototype mold (commonly made from aluminum or resin).
  • Within 7–10 working days, we produce the first sample parts using the prototype mold and send them to you for evaluation.
  • This sample stage is crucial. Please inspect carefully for fit, size, structure, and overall aesthetics.

Step 3: Sample Revisions (If Needed)

If the sample requires modifications:

  • We gather your feedback and adjust the design or mold accordingly.
  • Revised samples are produced and sent again for your approval.
  • We repeat this step as necessary until the sample is fully approved.

Step 4: Mass Production Mold Development

Once the sample is finalized and approved:

  • You’ll pay the mass production mold fee.
  • We will then start building the final production-grade mold, which is designed to withstand high-volume output with long service life.
  • This process takes approximately 30 working days.

Step 5: For Printed Cups – Logo Printing & Proofing

If your product includes printed elements (e.g., printed PP or PET cups):

  • You’ll need to provide a high-resolution logo file in AI, PDF, or PSD format.
  • We will create a printing plate (silk screen or offset, depending on method).
  • After your confirmation of the digital proof, we proceed with a printed sample.
  • Only after your approval of the printing result will we begin mass production printing.

Why Brands Choose Dashan for Custom Thermoforming

✅ End-to-end engineering support
✅ Quick sample turnaround (7–10 days)
✅ Accurate and efficient mold-making (30 days average)
✅ Custom printing for branding
✅ Experienced in PP, PET, PLA, CPET and more

Whether you’re launching fruit trays, dessert clamshells, takeout lunch boxes, or printed beverage cups, our custom tooling process ensures the perfect match between design, functionality, and manufacturability.

Conclusion

Custom blister and thermoformed packaging starts with the right process—and the right partner. At Xiamen Dashan, we combine expert mold design, high-quality materials, and flexible production to meet your exact needs. From sample to final delivery, you’ll be guided every step of the way.

📩 Have a packaging idea? Get in touch with our team to start your custom tooling project today.