Hardware Blister Packaging.

We run a heavier gauge of PET or PVC for hardware and shape the cavity so threads and points don't press on a thin wall. Thin film tears at the corners where a fastener's edge rests against it. Multi-cavity tooling also stops the pieces grinding against each other on the way to the store.

Tell us the heaviest and sharpest item in the range so we set the gauge for that one.

The weight of metal hanging from a thin card pulls on the peg hole until it rips. We answer that with heavier card stock, a reinforced peg zone and a seal rated to the load, because the card carries the weight and the blister only holds the parts.

Before a run, we hang filled samples on a peg and shake them with the real fasteners inside.

It gives each fastener or group its own pocket, so the count stays visible and the parts don't bunch in one corner. Loose screws in a single bubble slide to the bottom, rattle and look like a short count. Separate cavities let the buyer see exactly how many are in the pack.

Spreading the parts out also spreads the weight across the card, which takes strain off the seal.

Lead with the size in trade notation, the count and the use, in type large enough to read from across the aisle. Application photos and simple icons help buyers match the part to the job. Brand colour can code each product line so a whole peg wall reads as one system.

We print the card in CMYK and can add spot UV to a logo or a size callout.

Hardware cards usually run from 4 × 6 in up to 8 × 12 in, measured flat across the printed face. Small screw packs sit at the lower end, while hand tools and bit sets need the larger formats. The blister has to leave a margin of card all round for the seal.

Once a product gets heavier than a card can carry, we'd move it to a trapped blister or a small printed box.

Bits, blades and higher-value tools usually move up to a trapped blister, where the bubble is locked between two card layers. The pack can't be peeled open on the shelf, which matters for small items that tend to walk out of stores. Parts used over a project suit a resealable build that the buyer can close again.

Contractor quantities often outgrow blisters altogether and go into printed boxes.

Hardware blister runs start at 500 units. The top of our range is 100,000, which covers most regional and national peg-wall programs.

Ranges that share one card size with different cavities keep the printed set consistent along the wall, and they're simpler to reorder together.

Expect 7 to 10 business days in production, with a rush option of 5 to 7. We send samples within 5 to 7 business days, filled with your own fasteners if you ship some over, so the peg-shake test happens before bulk. You get the sample fee back as a credit on the production order.