Thermoform Packaging Design


Dordan is skilled with developing thermoform designs from scratch and importing customer-provided designs to optimize for the thermoforming process. Dordan utilizes Solid Model NX for the design and development of its thermoform packaging designs.

Custom Thermoform Designers

Family-owned, thermoform designer and manufacturer since 1962.

A thermoformed part is only as good as the tool on which it is formed. Dordan is a fully-integrated thermoform supplier with in house design, tooling, manufacturing, and cleanroom thermoforming capabilities. As both a thermoform designer and manufacturer, Dordan engineers parts for consistently high quality production.

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Plastic Thermoform Design Types

60-years of thermoform design experience.

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Dordan Thermoform Engineering Process

Cross departmental collaboration | NX thermoform designs | NX CAM/CNC tooling

  • Before beginning the formal packaging design process, management from engineering, production, and quality control review the project requirements to determine a risk-based strategy for mitigating potential thermoforming challenges.

  • Dordan utilizes Solid Model NX for the development of its thermoform designs. Our design team is skilled with reverse engineering physical products and importing customer-provided model files.

  • Dordan submits engineering drawings, photorealistic renderings, and prototypes for customer review and approval prior to machining the prototype tool. The function of thermoformed prototypes is to demonstrate part form, fit, and function, while simultaneously proving out the tool paths for the machining of the production tooling.

  • After prototype approval, the tool paths are replicated utilizing the same NX CAM programming to CNC machine the production tooling (step and repeat). All thermoform tooling components like assist plugs, die-build ups, end-of-arm tooling, pressure boxes, etc., are machined in house and hand polished and assembled.

  • The same team of packaging engineers that design the thermoform part also develop the NX CAM/CNC produced thermoform tooling, which allows for more intelligent quality control, because there are no machining or software translation errors between design, tooling, and production.

  • Before the first run of a new job, engineering, production, and quality control management regroup to address potential problem areas and determine critical features for continuous quality control inspection and documentation.

  • Dordan's thermoform design process is managed by its ISO 9001:2015 certification, which guarantees document control, rev# traceability, design retention, etc.

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