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Thermoformed trays

Custom thermoformed trays engineered for product protection, organization, handling, and automated manufacturing applications

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Thermoformed dunnage tray
automotive dunnage tray

Custom thermoformed trays

Thermoformed trays are custom plastic packaging and handling solutions produced by forming plastic sheet over custom tooling. Cavities and other formed features are designed around the shape and dimensions of the packaged product and the requirements of the application.

Dordan designs and manufactures thermoformed trays in-house, with engineering, prototype and production tooling, thermoforming, and quality control supporting the complete tray development process.

Tray applications include:

  • Dunnage & shipping trays

  • Assembly & WIP trays

  • ESD & conductive trays

  • Insert & retail trays

Thermoformed tray categories

Find the right tray for your application

Explore custom thermoformed tray solutions for industrial, electronics, automotive, and consumer applications.

Thermoformed assembly tray

Assembly & WIP Trays

Custom thermoformed trays designed to organize, orient, and present parts throughout assembly and work-in-process manufacturing

Thermoformed shipping tray

Dunnage & Shipping Trays

Custom thermoformed trays engineered to protect and organize parts during handling, storage, transport, and distribution

ESD dunnage tray

ESD & Conductive Trays

Custom thermoformed trays manufactured from ESD and conductive materials for electronics and static-sensitive applications

Plastic insert tray

Insert Trays

Custom insert trays organize, protect, and present products within retail, consumer, and specialty packaging applications

Thermoformed tray design, tooling, & manufacturing

From thermoformed tray design through production

Custom thermoformed trays are developed and manufactured in-house, with integrated engineering, prototype and production tooling, thermoforming, and quality control.

thermoformed tray design

Tray Design & Engineering

Custom thermoformed trays are designed in Siemens NX around product geometry, tray function, handling requirements, and the thermoforming process. Engineering considers cavity layout, product retention and orientation, nesting and stacking, material distribution, and manufacturability before tooling is developed.

CNC for producing medical packaging thermoform tooling

Prototyping & Production Tooling

Prototype and production tooling is CNC-machined in-house from aluminum using NX CAM. Prototype tooling supports sample development and design evaluation before production tooling is finalized, allowing tray fit, function, handling, and manufacturability to be evaluated early in development.

Tray packaging thermoformer

Thermoformed Tray Manufacturing

Dordan manufactures custom thermoformed trays in-house across multiple thermoforming lines. Production capabilities support a range of materials, part sizes, and volumes, with robotic automation and dedicated cleanroom thermoforming available for application-specific requirements.

ISO 9001 certified thermoforming company

Thermoforming Quality Control

Tray programs are supported by Dordan's ISO 9001:2015 and ISO 13485:2016-certified quality management systems. First article inspection and project-specific dimensional requirements support consistent tray geometry and repeatable production, with additional validation and capability studies available when required.

Custom thermoformed tray development

Dordan develops custom thermoformed trays from initial design review through production. Each program begins by defining the product, application requirements, material, production needs, and manufacturing environment before engineering begins. 

  • Application & requirements review: Product geometry, performance functionality, critical dimensional tolerances, and material type are reviewed before engineering begins
  • Tray design & engineering: The tray is designed in Siemens NX and engineering reports and drawings are developed for review
  • Prototype tooling & samples: In-house prototype aluminum tooling is used to produce samples for evaluation
  • Customer evaluation & approval: Samples and engineering drawings are reviewed before production tooling is finalized
  • Production tooling: Production aluminum tooling is CNC-machined in-house using NX CAM
  • Thermoformed tray production: Following approval, the tray moves into production under ISO 9001-documented manufacturing and quality processes
thermoformed tray

Start your thermoformed tray project

Dordan provides custom tray design, tooling, and thermoforming for dunnage, assembly, ESD, and general industrial applications.

Request a Quote Call (815) 334-0087