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Custom thermoforming

Custom thermoforming of medical and industrial trays, blisters, and clamshells for product protection, assembly, material handling, and distribution

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Thermoforming with robotics
Custom plastics thermoforming
Custom thermoforming from prototype through production

Dordan manufactures custom thermoformed packaging for medical, industrial, electronics, automotive, and consumer applications. Our 50,000-square-foot facility combines thermoforming equipment, in-house tooling, automation, and quality control to support a wide range of materials, part geometries, and production volumes.

  • 14 inline thermoforming lines
  • Material thicknesses ranging from 0.010" to 0.125"
  • PETG, RPET/APET, RHIPS/HIPS, PVC, HDPE, PP, ABS, anti-static, static-dissipative, and conductive materials, and custom color matching
  • In-house machining of aluminum prototype and production tooling
  • Maximum mold size of 30" × 30" × 6"
  • Robotic automation and in-house end-of-arm tooling development
  • ISO 9001:2015 and ISO 13485:2016-certified quality management systems
  • ISO Class 8 cleanroom manufacturing for medical packaging
  • Prototype, mid-volume, and high-volume production capabilities

Markets served

Custom thermoforming across medical, industrial, electronics, and consumer markets

Dordan manufactures custom thermoformed packaging for applications ranging from medical device protection and ESD-sensitive components to industrial material handling and consumer product packaging.

Medical kit packaging

Medical Packaging

Custom thermoformed trays, blisters, and kits engineered for medical device protection, sterile barrier applications, and cleanroom manufacturing.

ESD dunnage tray

Electronics Packaging

ESD protective trays, dunnage, blisters, and clamshells designed for sensitive electronic components, assemblies, and material handling.

Thermoformed dunnage tray

Industrial Packaging

Custom thermoformed dunnage and assembly trays for component protection, work-in-process handling, automation, and shipping.

Thermoformed consumer packaging

Retail & Consumer Packaging

Custom blisters, clamshells, and insert trays designed for product visibility, protection, and retail presentation.

Integrated engineering, tooling, and thermoforming

Dordan brings packaging design, in-house tooling, thermoforming, and quality control together under one roof. By integrating these capabilities, our team can evaluate manufacturability early, refine designs before production, and maintain continuity from initial development through full-scale manufacturing.

Thermoforming tool

Let's talk about your project

Share your design and requirements with our team. We'll review your project and follow up the same business day, even if your specifications aren't finalized.

Contact Us Call (815) 334-0087