Dordan provides prototypes for customer evaluation and approval prior to building the production tooling. Dordan's prototypes are formed on a 1-up CNC-machined aluminum tool and are intended to demonstrate part form, fit, and function.
Above: Dordan's prototyping press
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.
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
What Sets Us Apart
In-House Design & Engineering
Design for Manufacturing Expertise
63 Years of Thermoform Design
4th-Generation Family Company Made in USA Since 1962
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