At Dordan, precision and performance start long before full-scale production. Our custom thermoformed packaging prototyping services help ensure your packaging solution performs exactly as intended — with no surprises during manufacturing.
What Are Thermoform Prototypes?
Thermoform prototypes are sample packaging parts created during the development process to test form, fit, and function before full-scale production. Made using the same or similar materials as the final product, these prototypes simulate the performance of the end-use thermoformed packaging and are a critical step in the design and validation process.
At Dordan, Thermoform Prototypes Are:
Precision-formed from custom prototype tooling: Produced in-house using CNC-machined prototype molds for fast turnaround and design flexibility.
Made from production-grade plastics: Allows for accurate assessment of durability, clarity, sealing performance, and aesthetic appeal.
Used for testing and validation: Ensures the packaging meets usability requirements—especially for medical and high-performance applications.
Essential for stakeholder approval and process refinement: Helps customers visualize and evaluate the design prior to investing in production 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: Drill bit machines aluminum prototype tooling in Dordan's tool and die shop
All Thermoform Prototypes Include:
A CNC-machined prototype tool
6–8 thermoformed samples for client evaluation (more available upon request)
Full support for testing and iteration to achieve optimal performance
Why Work With Dordan?
At Dordan Manufacturing, we combine over 62 years of thermoforming expertise with agile, in-house prototyping services to bring your custom packaging concepts to life—fast, accurately, and efficiently.
What Sets Us Apart
In-House Design & Engineering
Rapid Turnaround
Form-Fit Validation
Scalable Manufacturing
Industry Expertise
4th-Generation Family Company Made in USA Since 1962
Request a Free Design Consultation
Contact Us or a Request a Quote for a free thermoform design consultation today!