Abstract: A process for producing bubble-pack. Bulges are formed in a first sheet by a combination of mechanical pressure, vacuum and air pressure, without using the high temperatures associated with the prior art processes. A second sheet is sealed to the first sheet, opposite the bulges, by contacting the sheets and heating them only along the area of contact. The process of the present invention is suitable for forming bubble-pack from a wider variety of materials, notably HDPE, and bubble-pack with a lower weight per unit area, than are the prior art processes.