Thermoform prototyping is the process where the NX CAD design takes form. A single block of aluminum is CNC-machined into a "1-up" prototype mold, where plastic is then formed over and into.
Above: Prototyping press with cutting die and machined components for sampling complex geometries
At Dordan, prototypes are intended to demonstrate part form, fit, and function. We provide prototypes for customer evaluation and approval prior to building the production tooling. All prototypes are the same material type and thickness as the production parts, allowing customers to understand the durability and functionality of the packaging in the design stage. All thermoform prototyping include 6–8 samples for client evaluation (more available upon request), and full support for testing and iteration to achieve optimal performance.
Dordan's prototype tooling is generated by the same engineers who developed the packaging design. This integration between design and prototyping allows for fast iterations and a deep understanding of the relationship between thermoform design and tooling.
Our prototyping process includes:
Before machining aluminum prototype tooling, we create 3D-printed prototype molds to quickly thermoform preliminary samples. This allows for early evaluation of form, fit, and functionality, giving clients a fast and cost-effective way to validate design performance.
With client approval, we then move into formal prototyping using CNC-machined aluminum tooling. These 1-up prototype tools are developed by the same engineering team that designs the thermoformed part, ensuring a seamless transition from concept to production.
Our packaging engineers use NX Solid Modeling and NX CAM programming to generate tool paths for both prototyping and final tooling — reducing translation errors and ensuring part consistency from prototype to production.
If the prototype doesn’t meet expectations, we revise the design and tool until it does. Prototyping is included in the cost of tooling and is considered a critical step in our thermoform development process.
Once the prototype is approved, the validated tool paths are replicated to create multi-cavity production tooling using our in house CNC equipment. This "step and repeat" method eliminates the risk of design-to-tool translation errors and ensures the production thermoforms match the prototype exactly.
Above: Machining thermoform prototype tooling out of a solid block of aluminum
What Sets Us Apart
In-House Design & Tooling
Design for Manufacturing Expertise
63-Years of Thermoform Prototyping Experience
4th-Generation Family Company Made in USA Since 1962
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