Dordan Manufacturing designs and manufactures custom thermoformed medical handling trays for safe transport, assembly, and automation integration. Available for production in our ISO Class 8 certified cleanroom or standard production facility, our trays are engineered for precision, cleanliness, and repeatability—making them ideal for medical device manufacturers, contract packagers, and automation-driven assembly environments.
What Are Medical Handling Trays?
Medical handling trays are rigid thermoformed trays used to organize, protect, and transport medical components throughout assembly, kitting, or shipping operations.
These Trays:
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Ensure device protection during intra-facility or external transport
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Are designed for stacking, nesting, and robotic handling
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Support automated assembly line integration
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Offer particulate control through cleanroom and ESD-compatible materials
Key Features of Thermoformed Medical Handling Trays
Whether used as medical component assembly trays, sub-component dunnage trays, or medical shipping trays, Dordan’s thermoformed solutions offer the precision and reliability medical manufacturers demand:
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Stackability & Load-Bearing Design
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Engineered to stack and rotate without product contact
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Perimeter support protects sensitive components from compression damage
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Tight Form & Cut Tolerances
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Designed with automation in mind
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Tighter-then-standard tolerances to ensure trays perform consistently in high speed environments.
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Custom Locating Features
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Formed guide slots and locators enable intelligent integration with robotic assembly equipment
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Trays act as both component protectors and assembly enablers
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Cleanroom & ESD Compatibility
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Trays are thermoformed in our ISO Class 8 cleanroom to meet industry cleanliness standards
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ESD-safe materials available for electronic and sensor-containing medical components
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Fully Integrated Tray Design & Manufacturing
As a vertically integrated thermoformer, Dordan provides complete medical handling tray development under one roof. By maintaining control over the entire tray lifecycle, Dordan delivers repeatable, performance-based packaging that saves time, reduces defects, and meets regulatory and production requirements.
Inhouse Services-
NX Solid Modeling Design: Precise CAD design of form and function for handling, automation, and assembly
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CNC Machined Prototype & Production Tooling: Designed and produced in-house by the same team that engineers the tray
- Plastics Thermoforming: 13 state-of-the-art thermoforming machines capable of converting 100MM lbs. of material annually
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ISO Class 8 Certified Cleanroom Thermoforming: Hard-wall cleanroom with monitored particulate levels for medical-grade manufacturing
Markets We Serve
Dordan’s custom medical handling trays are used by leading medical device OEM's and their supply chain partners that require cleanroom-compatible packaging for part protection, staging, and assembly.
Medical Device Manufacturers: We design and manufacture thermoformed handling trays to protect and organize components like catheters, implants, surgical tools, and tubing sets during manufacturing, sterilization, and transport.
Contract Manufacturers & Assemblers: Our trays integrate seamlessly into automated and manual assembly lines, helping to optimize workflow, reduce contamination risk, and ensure repeatable part orientation throughout cleanroom environments.
Pharmaceutical & Diagnostic Companies: From test kit components to drug delivery systems, Dordan’s handling trays are used to stage and protect sensitive items during kitting, filling, and packaging operations under sterile or low-particulate conditions.
Medical Packaging Suppliers & Distributors: We support supply chain partners who require consistent, high-quality handling tray solutions for integration into broader packaging systems used in sterile barrier, procedural, and secondary packaging.
Cleanroom Manufacturing for Medical Handling Trays
At Dordan Manufacturing, we recognize the critical importance of maintaining a contamination-controlled environment when producing medical handling trays. Our ISO Class 8 certified cleanroom is specifically designed to meet the stringent cleanliness standards required for medical device packaging and component handling.
Key Cleanroom Capabilities:
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Precision Equipment for Complex Geometries: Our cleanroom is outfitted with high-performance Keifel thermoformers, capable of forming intricate tray designs with consistent wall thickness and tight tolerances.
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Controlled Airflow & Particulate Monitoring: The facility utilizes HEPA-filtered, cascading airflow systems and undergoes regular particulate count testing to ensure compliance with ISO 14644 standards.
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Dedicated Zones for Gowning & Material Flow: Separate entry points for personnel and raw materials reduce cross-contamination risk, supporting uninterrupted cleanroom operations.
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Validated Sanitation & Maintenance Protocols: Routine deep cleans and documented maintenance schedules ensure cleanliness and process integrity between and during production runs.
Handling Tray Quality Control
At Dordan, every medical handling tray is manufactured under a robust, documented Quality Management System that ensures consistency, compliance, and performance.
Our Quality Control Processes Include:
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Risk-based approach for tray design and tooling strategies aimed at reducing cost and improving functionality
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First Article Inspection (FAI) for new tray designs
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First Article Validations (FAV), a more thorough FAI
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In-process and final inspections including a final production drawing with manufacturing tolerances
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Process capability studies (CPK) using automated optical inspection equipment
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Lot traceability and material certification for regulatory compliance
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Cleanroom protocols to manage particulate and bioburden levels
From prototype through full production, our cross-functional quality and engineering teams work together to validate that every tray meets the specified form, fit, function—and cleanliness—your application requires.
Why Choose Dordan?
What Sets Us Apart:
Cleanroom-Ready Manufacturing in USA
ISO 13485:2016 Certified Quality
Custom-Engineered for Functionality
Speed, Precision & Control
Trusted 4th Generation Family-Owned Partner Since 1962
Request a Quote for Custom Medical Handling Trays
Looking for a reliable supplier of thermoformed medical dunnage trays or custom handling trays for assembly, automation, or shipping? Contact Us or Request a Quote today to start your project with Dordan.