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Thermoformed trays

Custom thermoformed trays engineered for product protection, material handling, manufacturing, and presentation

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Thermoformed dunnage tray
Medical device tray

Custom thermoformed trays

Thermoformed trays are custom plastic packaging and handling solutions formed to the dimensions and functional requirements of a product. Formed cavities can protect, locate, separate, orient, and present products during manufacturing, transportation, packaging, and end use.

Tray design varies by application. Medical device trays can provide device protection and support sterile barrier packaging requirements, while industrial dunnage and assembly trays are designed for part handling, orientation, automation, and manufacturing workflows. Insert trays organize and present products within secondary packaging.

Dordan designs and manufactures custom thermoformed trays around product geometry, handling requirements, manufacturing processes, and package performance.

  • Medical device trays
  • Dunnage and assembly trays
  • Insert and retail trays
  • ESD and conductive tray applications

Thermoformed tray categories

Find the right tray for your application

Explore custom thermoformed tray solutions designed around product protection, handling, manufacturing, and presentation requirements.

Medical device tray

Medical Device Trays

Custom thermoformed trays designed to support medical device protection, sterile barrier packaging compatibility, and healthcare manufacturing requirements

Thermoformed dunnage and assembly trays

Dunnage & Assembly Trays

Custom thermoformed trays engineered for part protection, organized transport, assembly operations, and repeatable manufacturing workflows

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 from initial package design and prototype tooling through production. Integrated engineering, tooling, thermoforming, and quality systems support consistent tray development and production.

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 for medical, industrial, electronics, consumer, and manufacturing applications. Production capabilities support trays designed for product protection, assembly, material handling, automated processes, packaging, and presentation.

thermoforming quality control

Thermoformed Tray Quality

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 application review through production. Each tray program begins by defining the product, tray function, handling requirements, material, production needs, and manufacturing environment that will influence the thermoformed tray design.

  • Application & Requirements Review: Product geometry, tray function, handling methods, material requirements, production volume, and application-specific requirements are reviewed before engineering begins
  • Thermoformed Tray Design & Engineering: Custom trays are designed in Siemens NX around product fit, protection, retention, orientation, material distribution, and manufacturability
  • Prototype Tooling & Samples: Prototype aluminum tooling is CNC-machined in-house to produce sample thermoformed trays for evaluation of fit, function, handling, nesting, and stacking
  • Customer Evaluation & Approval: Sample trays and engineering drawings are reviewed to confirm the thermoformed tray design meets product and application requirements before production tooling
  • Production Tooling: Production aluminum tooling is CNC-machined in-house using NX CAM for consistent cavity geometry, material distribution, dimensional control, and repeatable thermoforming
  • Thermoformed Tray Production: Following approval, custom thermoformed trays move into production under documented manufacturing and quality processes
thermoformed tray packaging

Start your thermoformed tray project

Custom thermoformed trays engineered for product protection, efficient handling, and manufacturing performance

Request a Quote Call (815) 334-0087