Frequently asked questions

Dordan manufactures custom thermoformed packaging for medical, industrial, automotive, electronics, consumer, and retail applications.

Products include medical device trays and blisters, surgical and procedural packaging, medical clamshells, dunnage trays, ESD packaging, protective clamshells, blisters, insert trays, and handling trays for manufacturing, assembly, inspection, distribution, and point-of-sale presentation.

Each package is engineered around the product, material, manufacturing process, quality requirements, and end-use application.

Yes. Dordan provides in-house package design, engineering, prototyping, tooling, and thermoforming support for custom packaging programs.

Our engineering team uses Siemens NX to develop package concepts, cavity layouts, and tooling designs around product dimensions, material selection, automation requirements, and manufacturing conditions. Prototype aluminum tooling is CNC-machined in-house to support form, fit, and function review before production tooling is built.

By combining engineering, tooling, thermoforming, and quality under one roof, Dordan helps streamline package development from concept through production.

To prepare a packaging quote, Dordan typically reviews the product being packaged, estimated production volume, material preferences, performance and quality requirements, and any available CAD files, drawings, or physical samples.

Quotes are developed around the complete manufacturing program, including part size, material selection and gauge, production volume, tooling requirements, and inspection and validation requirements. Every project is reviewed for manufacturability, and if design changes are recommended to improve production, those recommendations are discussed during the quoting process.

For assembly or automation applications, fixture model files, equipment information, or additional process details may also be requested. Material pricing and production volumes also influence piece price, with higher production volumes typically reducing unit cost. Dordan sources materials through established domestic supplier relationships to support reliable supply and pricing.

Projects typically begin in one of three ways: a new package design, replication of an existing package, or redesign of an existing package.

For new designs, Dordan reviews the product, available CAD files or samples, application requirements, material preferences, production volume, handling needs, and performance goals. For replicated or redesigned packages, Dordan reviews the existing package, CAD files, drawings, or physical samples along with the requirements for matching or improving the current design.

Our engineering team develops package concepts in Siemens NX with engineering reviews focused on product fit, retention, manufacturability, automation compatibility, tooling approach, and end-use performance.

Once the design is approved, prototype aluminum tooling is CNC-machined in-house to produce samples for form, fit, and function review. After approval, production tooling is built and the package moves into thermoforming manufacturing, with inspection, validation, and documentation completed as required by the program.

Dordan thermoforms a variety of plastic materials based on package design, application requirements, and manufacturing conditions.

Common materials include virgin and recycled PET, HIPS, PETG, PP, PVC, HDPE, and Anti-Stat, ESD, or conductive materials for electronics handling applications.

Medical packaging programs may require materials compatible with cleanroom manufacturing, sterilization methods, sealing systems, and customer specifications. Material selection is reviewed during design and quoting to support product protection, forming performance, visibility, rigidity, recyclability, and end-use requirements.

Custom thermoformed packaging costs vary based on package size, material, gauge, production volume, material utilization, and manufacturing requirements.

Custom thermoforming projects require one-time production tooling before manufacturing begins. Tooling cost is typically based on the tooling platform required for the project, including whether the package runs on a smaller or larger thermoforming machine.

Final pricing is also influenced by material purchasing minimums, package complexity, and production requirements. Dordan reviews these factors during the quoting process to provide accurate tooling, piece-price, and production cost estimates.

Minimum order quantities vary by package design, material, gauge, and production volume requirements.

Because thermoformed packaging is produced from plastic sheet, MOQs are often driven by material purchasing minimums. Larger or heavier-gauge parts may meet those minimums at lower unit quantities, while thinner-gauge blisters or smaller parts may require higher production volumes.

MOQ requirements are reviewed during the quoting process and determined on a project-by-project basis.

Yes. Dordan manufactures thermoformed medical packaging in an ISO Class 8 cleanroom supported by an ISO 13485:2016-certified quality management system.

Cleanroom manufacturing supports medical device trays and blisters, surgical and procedural packaging, medical clamshells, and component handling trays that require a controlled production environment.

Medical packaging programs may include documented production processes, material traceability, inspection requirements, cleanroom handling procedures, and validation activities based on customer and regulatory requirements.

Dordan maintains ISO 9001:2015 and ISO 13485:2016-certified quality management systems supporting consistent thermoformed packaging production.

Quality procedures are integrated throughout manufacturing, including documented inspection plans, material traceability, process controls, and part inspections. Medical and cleanroom programs may include First Article Validation (FAV), IQ/OQ/PQ support, PPAP documentation, and automated optical inspection (AOI) based on program requirements.

These systems help ensure packaging is manufactured to specification and supported by documented quality records throughout production.

Medical thermoformed packaging costs vary based on package size, material, gauge, production volume, tooling requirements, and program specifications.

Medical packaging programs may also require ISO Class 8 cleanroom manufacturing, validation activities, documentation, inspection requirements, and materials compatible with sterilization methods such as EtO or gamma irradiation. These requirements are reviewed during the quoting process and may influence overall program cost.

Because every medical packaging program is unique, Dordan evaluates part geometry, production requirements, validation needs, and quality expectations to provide accurate tooling, piece-price, and production cost estimates.