We engineer and build all custom thermoform tooling in-house. As a fully integrated thermoformed packaging manufacturer, we maintain complete control over the design, prototyping, CNC machining, and assembly of all tools—ensuring faster lead times, tighter tolerances, and superior product consistency.
Above: One of Dordan's CNCs for machining thermoform tooling
Our tool shop allows us to design, machine, and assemble all prototype and production thermoform tooling under one roof. Unlike outsourced tooling models, Dordan’s packaging engineering department is fully responsible for developing both the thermoformed part design and the corresponding CNC-machined tooling. This direct integration results in a smarter, more controlled, and highly repeatable thermoforming process.
We design and manufacture all thermoform tooling in-house to ensure:
Speed and Accuracy: CNC-machined aluminum molds and components deliver tight tolerances and repeatable results.
Customization: Each tool is engineered for the specific part geometry, material, and forming capabilities.
Scalability: From prototype molds to multi-cavity production tools, our tooling supports projects of all volumes.
Dordan uses NX CAM programming and CNC machining centers to produce both 1-up prototype tools and multi-cavity production tooling. During the prototyping stage, our engineers develop and test the tool paths that will later be used for production tooling—eliminating translation errors and improving process consistency.
By replicating validated tool paths (step-and-repeat) from prototype to production, we reduce variation and improve quality assurance across the full production lifecycle.
We design and build all ancillary tooling components in-house, including: Assist plugs, pressure boxes, water plates, die build-ups, trim headers, locators, movable undercut mechanisms, and end-of-arm-tooling for robotic pick and place operations. These components are machined using the same NX CAM and CNC platforms as the form tools, ensuring compatibility and control throughout every phase of production.
Dordan specializes in the design and manufacture of cleanroom-specific thermoform tooling to support medical packaging produced in our ISO Class 8 cleanroom. Cleanroom tooling is engineered with precision components and specialized features to ensure compliance with stringent regulatory and performance requirements. Our cleanroom tooling capabilities include:
Tight-tolerance CNC-machined aluminum molds are designed for consistent forming of sterile barrier systems and other medical packaging.
Syntactic foam plug assists enhances material distribution and clarity for deep-draw or thin-gauge parts.
Heated steel rule cutting dies ensure clean, accurate cuts within the cleanroom forming environment.
Tool designs optimized for sterilization compatibility supports downstream EtO, gamma, or steam sterilization processes.
Dedicated cleanroom tooling validation protocols that evaluate dimensional accuracy, repeatability, and cleanliness before production.
By integrating cleanroom tooling with our in-house design, forming, and quality control, Dordan ensures the compliant production of medical device trays, blisters, kits, and handling trays for critical medical applications.
We are certified to ISO 9001:2015 and ISO 13485:2016 standards. All thermoform tooling is measured, verified, and quality-checked by the same team that developed the thermoform part design. Tooling and components are machined to near flatness, allowing for consistent material distribution and die cutting.
All production tooling is customer-owned and stored in our temperature-controlled warehouse for ongoing maintenance, re-runs, and inventory tracking.
63 Years of Thermoform Tooling Experience
ISO Certified Thermoform Packaging Supplier
Risk-Based Engineering and Design for Manufacturing
4th-Generation Family-Owned Since 1962, Made in USA
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