The thermoformed design is helping Cook Urological, a leading global medical device manufacturer, significantly reduce packaging costs by slashing tooling costs, per package costs and assembly costs. Prent’s universal thermoformed clamshell accommodates 35 different Nitinol Basket product line options, including two different handle configurations. The baskets are used for urinary tract stone manipulation and removal. This packaging design help Cook reduce its packaging costs three ways,First, the one-piece design is slashing tooling costs because it is thermoformed using just one tool —rather than separate tools for trays and retainers.Second, it cut the cost per package by more than 25% with the one-piece design. Third, less assembly time is now required. In addition, pouch abrasion is eliminated due to the design and location of a small, strategically placed fold-over hinge. The one piece design—coupled with four undercut features inside the circular cavity—has improved the ease and control of loading and unloading the delicate spiral medical devices. The undercuts also reduce product damage and prevent the medical device from popping out of the package or out of the operating room’s sterile field.