Toy Blister Packaging with Header Card.

Toy header cards are usually printed on 14 to 18 pt board with a heat-seal coating on the face. The coating is what bonds the formed blister flange to the card under heat and pressure. Heavier toys go toward the 18 pt end so the card and peg hole don't bend on the wall.

Thinner cards are fine for light figures and small accessories.

Yes, we tool accessory wells into the same blister so each piece sits in its own pocket beside the main figure. The cavity is formed true to the toy, which keeps parts from sliding and scratching one another in transit. Collectors expect a composed layout with every accessory in view.

Send final production samples of every piece so the wells fit tightly.

Yes, collector packs are designed to stay sealed and still look sharp years later. That means clean card corners, a coating that resists scuffing and a PET blister that won't yellow the way older PVC can. Retail packs meant to be opened can use a simpler card with a strong seal.

Tell us early if the line will be graded, because corner shape and coating are settled at the dieline stage.

Toy cards usually get full CMYK in saturated colour, and spot UV can pick out the character or logo. Foil is kept for chase variants so a rare version is easy to spot on the peg. Size the key message for a child's eye level, which sits below the header rather than above it.

Leave a clear area on the card for the age grading marks and any licensor approval stamp.

Toy header cards commonly run from 6 × 9 in to 10 × 14 in, measured flat. Pick the size from the toy plus a card margin for the seal, then check it against the peg spacing at your retailers. The header above the blister needs enough height for the character art and the hang hole.

We reinforce the peg area on larger cards so heavy toys don't tear out.

We would go with PET or RPET for new toy lines, and keep PVC for legacy tools that already run it. PET is clear, forms cleanly around detailed shapes and is easier to place in recycling streams. PVC forms well at a lower cost, but some retailers now ask brands to move away from it.

The heat-seal coating on the card is matched to whichever sheet you choose.

The floor for toy blister cards is 500 units. Collector lines and chase variants often run small, and that floor lets you test a character before committing to a full wave of up to 100,000.

Build licensed art approvals into the schedule before we book the run, since they're usually the slowest step.

Once you and your licensor approve the art, production takes 7 to 10 business days. A rush run takes 5 to 7. Sealed samples on printed cards take 5 to 7 business days, and they're often what the licensor signs off. The sample fee is taken off your production bill.