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Die-cut components and cards

Cards and film parts that hold and protect

Components sit inside the package with the device. Rigid HDPE cards hold it in place. Thin film parts line, cover, and separate. We die-cut both in our ISO Class 8 cleanroom, with quick-turn prototypes and no minimum order.

Cut in our cleanroom
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Fit

When to choose die-cut components and cards

  • The device moves inside the package

    A mounting card holds the device in place in a chevron pouch or rigid tray.

  • A sharp tip or edge could damage the packaging

    A card helps keep sharp points away from the pouch or lid in transit.

  • Parts need a liner, cover, or separator

    Flexible film components line, protect, and interleave without adding stiffness.

  • You want cards on the same order as your lids and pouches

    Order cards and film parts on the same purchase order as your lids, rollstock, and pouches, with one contact for quotes, deliveries and quality questions.

  • You need to match a validated card or film part

    Send the current spec, revision and material callout, including card thickness or film gauge. We cut to it as written and don't substitute material without your written approval.

Cut in our cleanroom

What we offer: die-cut components and cards

  • Cut in our cleanroom

    HDPE mounting and insert cards

    Rigid HDPE cards, 10–35 mil (0.25–0.89 mm), die-cut in our cleanroom to hold and protect devices in chevron pouches and rigid trays.

    Format
    Die-cut eaches or rollstock
    Size / gauge
    10–35 mil (0.25–0.89 mm)
    Sterilization
    EtO, gamma, e-beam
  • Cut in our cleanroom

    HDPE/LDPE film die-cut components

    Flexible HDPE/LDPE film parts, 28–60 µm (≈1.1–2.4 mil), die-cut in our cleanroom: liners, protective layers, and interleaves.

    Format
    Die-cut eaches
    Size / gauge
    28–60 µm (≈1.1–2.4 mil)
    Sterilization
    EtO (conditional), gamma, e-beam

At a glance

Compare die-cut components and cards
ProductFormatMaterialWeight, gauge or sizeMadeSterilization
HDPE cardsDie-cut eaches or rollstock100% virgin HDPE10–35 mil (0.25–0.89 mm)Cut in our cleanroomEtO, gamma, e-beam
HDPE/LDPE film componentsDie-cut eachesMedical-grade HDPE/LDPE film28–60 µm (≈1.1–2.4 mil)Cut in our cleanroomEtO (conditional), gamma, e-beam

The basics

What to know before you specify or re-source

Rigid cards vs flexible film

Cards are stiff: 10–35 mil (0.25–0.89 mm) HDPE. They carry and position the device and keep it from shifting in a chevron pouch or rigid tray. The same HDPE is also available on rolls, wound on plastic cores, as plain web for lines that cut their own cards.

Film parts are thin and flexible: 28–60 µm (≈1.1–2.4 mil) HDPE/LDPE. They do not hold a device. They line, cover, or separate. Not sure which you need? Send a spec and we will tell you.

Sterilization with cards and film

HDPE cards and film parts are compatible with EtO, gamma and e-beam. Neither is porous, so for EtO they go inside a package with a porous side, such as a Tyvek® or paper pouch or lid. Place them so they don't block the gas path to the device, especially where film wraps or covers it, and confirm EtO penetration and aeration in your own validated cycle.

FAQ

Die-cut components and cards: common questions

All FAQs

What is the difference between cards and film components?

Both are cut in our ISO Class 8 cleanroom:

  • HDPE cards are rigid, 10–35 mil (0.25–0.89 mm), and hold a device in place.
  • HDPE/LDPE film components are flexible, 28–60 µm (≈1.1–2.4 mil), and work as liners, protective layers and interleaves.

Can I get the pouch and the card from you?

Yes. We cut the cards in our cleanroom and supply chevron pouches and header bags sourced from qualified manufacturers. You get both on one purchase order with one point of contact. Tell us the pouch size and we will size the card to fit.

What should I send for a quote?

Send:

  • A spec or CAD file.
  • The material and thickness.
  • The pouch or tray the part goes into.
  • Your sterilization method.
  • Quantities and timeline.

For cards, tell us whether you want pre-cut shapes or rollstock on cores.

Start a project

Have a spec or a CAD file? Send it over.

Yours or your customer's, or a sketch if there's no spec yet. We'll reply within one business day with questions, then a quote and a sample plan.

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