Point of Care Diagnostics Packaging: Blister Packs

Diagnostic reagent blister design & manufacturing

As decentralized healthcare delivery models become increasingly popular, the demand for a broader range of diagnostic tests closer to patients continues to rise.

Life Science Outsourcing guides diagnostics companies toward quicker, more cost-effective commercial launches of innovative microfluidic diagnostic products with microfluidic cartridge and reagent blister pack manufacturing capacity ranging from a few thousand to tens of millions of units annually.

Reagent blister packs tailored to your needs

Companies developing new or enhanced point-of-care tests often find themselves confined to large contract manufacturers’ inflexible platforms and strict throughput requirements.

Life Science Outsourcing offers turnkey reagent blister design, testing, process development, and manufacturing, providing single-source program guidance and execution for the entire duration of a project, from initial design prototyping to full commercial production.

Our highly automated production methods guarantee precise reagent filling and packaging for superior stability and more consistent clinical outcomes.

Blister samples & sample kits available

If you’re concerned that your current blister manufacturer cannot meet your requirements, or you’re evaluating diagnostic reagent blister contract manufacturers, Life Science Outsourcing offers diagnostic reagent blister development kits that allow customers to test lab-on-a-chip reagent blisters with their chosen microfluidic formats.

Samples are provided in various sizes and fill volumes. We can also fill blisters with your unique reagents in small volumes. To learn more or order, click here.

Microfluidic cartridge and reagent blisters prototyping and contract manufacturing Life Science Outsourcing offers essential blister design assistance to meet unique customer requirements in a validated blister platform that can be consistently manufactured.

We use the same equipment for prototyping as specified for commercial production. If that requires equipment we don’t already have in-house, we’ll make the investment.

We customize according to the following specifications:

  • Blister pack fill volume
  • Blister shape, size, and other dimensional characteristics
  • Microfluidic cartridge manufacturing
  • Console actuating force
  • Reagent blister pouch automation
  • Quantity

Our processes are designed for modularization, enabling us to produce our own tooling swiftly when needed.

Testing & validation

On-site testing includes inspecting reagent blister pack fill volume, seal strength, and dimensional stability. We validate reagent blister filling and sealing using accelerated aging studies to assess the impact of time on seal strength, forming the basis for reagent blister shelf life claims.

Process development

We develop reagent blister forming, filling, and sealing processes tailored to customers’ specific product requirements. We follow a design of experiments (DOE) approach to develop your process parameters.


Life Science Outsourcing offers manual, semi-automated, and fully automated diagnostic reagent blister packaging and microfluidic cartridges in-house and customizes processes based on suitability to the customer’s unique commercialization needs.

Process development employs the same forming, filling, and sealing technologies as full-scale production to ensure a consistent, high-quality product once production begins.

Supply chain management

As a leading reagent blister pack manufacturing partner for over two decades, we’ve established an extensive network of suppliers of standard and custom blister foils, lidding, and ISO-certified custom reagents.

Meeting unique requirements

For more intricate designs or more sensitive reagent selections, Life Science Outsourcing possesses unique processing capabilities in the areas of degassing mineral oil to low-oxygen levels and 100% filling.

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