When developing custom thermoformed packaging, lead times are an important consideration. Customers understandably want to move quickly from concept to production. However, successful packaging development requires more than designing the part itself. It demands a thorough understanding of customer requirements, the complete packaging lifecycle, and sound engineering principles to ensure consistent manufacturing.
At Dordan Manufacturing, engineering begins long before the first CAD drawing. Our development process identifies potential challenges early, reduces manufacturing risks, and helps packaging solutions transition efficiently into production.
Thermoforming equipment at Dordan Manufacturing's Woodstock, IL facility
Every project begins with a comprehensive review of customer requirements, which Dordan's account manager documents in a formal engineering report.
The review addresses fundamental requirements, including:
Additional considerations depend on the application and may include:
Exploded CAD rendering of custom thermoformed packaging and components
Once the engineering report is prepared, Dordan's engineering manager meets with the production manager to review project requirements and assess potential manufacturing challenges before detailed design begins.
If clarification is needed, the account manager works directly with the customer to resolve outstanding questions.
Engineering for manufacturing, not just appearance
With project requirements established, Dordan's engineering manager develops the proposed packaging solution, balancing competing design priorities such as product protection, material efficiency, manufacturability, and cost.
The account manager receives a formal engineering report outlining the proposed approach and potential concerns for discussion with the customer.
Following this review, Dordan develops engineering drawings and CAD models that account for anticipated manufacturing tolerances based on practical thermoforming experience.
Engineering drawing of medical procedural kit tray
Using Siemens NX CAD and NX CAM, Dordan integrates package design with in-house tooling development, supporting the transition from approved engineering drawings to CNC machining.
Why design modifications affect lead time
Customer feedback is essential to custom packaging development, and Dordan welcomes design modifications as requirements evolve.
However, modifications vary in complexity. Some adjustments can be completed quickly, while others affect multiple design features, material distribution, manufacturing tolerances, or tooling requirements.
Because these factors are interconnected, a single modification may require additional engineering evaluation to ensure the revised design remains manufacturable and performs as intended.
From approved design to prototype to production tooling
Once the customer approves the engineering drawings, the project advances to tooling development.
A tooling engineer develops the CNC machining toolpaths used to manufacture aluminum prototype tooling. Prototype parts are then thermoformed, trimmed, and submitted to the customer for evaluation.
If adjustments are necessary, Dordan works with the customer to refine the design and produce updated prototypes. The time required depends on the complexity of the modifications.
Once prototypes are approved, the established toolpaths can be replicated across the production mold surface through a process known as step and repeat, supporting a consistent transition to production tooling.
CNC-machined thermoform tool
Transferring engineering designs to manufacturing
Before a new thermoformed package enters production, Dordan conducts a formal Production Control Plan meeting to transfer engineering design and development outputs to manufacturing.
This meeting brings together engineering, quality, and production management to review project requirements and establish the controls necessary for consistent manufacturing.
Every manufactured part at Dordan requires a custom Production Control Plan identifying critical product attributes, inspection methods, material specifications, tooling considerations, and production and packing requirements.
For medical packaging manufactured in Dordan's ISO Class 8 cleanroom, a separate Medical Production Control Plan addresses additional manufacturing and quality requirements, including applicable cleanroom controls, inspection procedures, and validation requirements.
For all cleanroom and PPAP projects, Dordan also conducts Failure Mode and Effects Analysis (FMEA) to identify potential failure modes, evaluate associated risks, and establish appropriate preventive measures.
These plans are developed using engineering documentation, customer requirements, and Dordan's established quality standards. They are reviewed and documented before initial production begins.
This formal transfer helps ensure that engineering specifications are understood, monitored, and maintained throughout production.
Dordan's ISO Class 8 cleanroom for manufacturing thermoformed medical packaging
How customers can help streamline packaging development
Two significant factors influencing development schedules are the completeness of initial requirements and the timeliness of customer feedback.
Providing accurate dimensions, tolerances, application requirements, and supporting documentation upfront minimizes subsequent clarification. Timely reviews and approvals also help maintain momentum through engineering, prototyping, and tooling.
Establishing critical requirements early positions the engineering team to develop solutions more efficiently.
Getting it right the first time
At Dordan, the objective is to translate customer requirements into a high-performing thermoformed part that can be manufactured reliably, with appropriate production and quality controls.
Achieving this requires technical experience, cross-functional collaboration, and thoughtful engineering.
Addressing important considerations early can help prevent costly modifications, unexpected performance issues, and production delays.
Good engineering isn't simply about how quickly a design is completed. It's about developing the right solution for the application—and getting it right before production begins.
Designing packaging for thermoforming
Explore key design considerations for developing custom thermoformed packaging that supports efficient manufacturing.