The process of designing a thermoformed blister package involves several steps. Here's a general overview of the process:

1. Define the Product: Determine the specific requirements of the product that will be packaged. Consider factors like size, shape, weight, fragility, and any special considerations or constraints.

2. Material Selection: Choose an appropriate material for the blister package. Typical materials include PVC (Polyvinyl chloride), PET (Polyethylene terephthalate), and PP (Polypropylene). The material should provide the necessary visibility, durability, and barrier properties for the product.

3. Design Concept: Create a design concept for the blister package. Consider factors such as the shape of the blister, the size of the card or backing, the placement of the product, and any branding or labeling requirements.

4. 3D Modeling: Use computer-aided design (CAD) software to create a 3D model of the blister package. This step allows you to visualize and refine the design, ensuring it meets the functional and aesthetic requirements.

5. Tooling and Prototyping: Based on the 3D model, develop the necessary tooling or molds for thermoforming. These molds will be used to produce the actual blister packages. Additionally, create prototypes to test the functionality and fit of the package with the product.

6. Packaging Testing: Evaluate the performance of the blister package through thorough testing. This can include assessing factors such as product stability, compatibility with the packaging material, tamper resistance, and ease of opening.

7. Production and Manufacturing: Once the design has been finalized and tested, the blister packages can be manufactured on a larger scale using the appropriate thermoforming equipment. The packages are produced by heating the plastic material, stretching it over the mold, and cooling it to form the desired shape.

8. Finishing and Assembly: After forming, the blister packages are trimmed and any necessary features or attachments, such as snap-tabs or hinged lids, may be added. These additional components can enhance functionality, convenience, and user experience.

9. Quality Control: Implement quality control measures throughout the production process to ensure that the blister packages meet the required standards. This can involve inspections, functional tests, and sampling.

10. Distribution and Packaging Line Integration: Finally, the blister packages are prepared for distribution and may be integrated into automated packaging lines for efficient filling and sealing.

It's important to note that the specific steps and considerations may vary depending on the complexity of the design, the industry, and the regulations applicable to the product packaging. Working with experienced packaging designers or manufacturers is recommended to ensure a successful thermoformed blister package design.