Thermoformed Dunnage & Assembly Trays | Custom Work-in-Process Packaging


Dordan Manufacturing is a family-owned dunnage tray designer and manufacturer with over 62 years of experience in custom thermoforming. Our thermoformed dunnage trays are designed to protect products, improve automation compatibility, and streamline shipping and assembly workflows for manufacturers and contract assemblers across automotive, industrial, electronics, and medical sectors.

Thermoformed dunnage tray

Key Dunnage Tray Benefits


  • Custom-Engineered Cavities: Designed to match the geometry of each part for a precise fit—preventing movement, damage, or misalignment during transport or automation.

  • Reusable & Durable: Made from impact-resistant materials like HDPE, HIPS, or RPET, dunnage trays are built to withstand repeated use in industrial environments.

  • Stackable & Automation-Compatible: Designed for easy stacking, storage, and integration with conveyor systems, robotic handling, and manual assembly stations.

  • Versatile Applications: Used in industries such as automotive, aerospace, medical device manufacturing, and electronics for part staging, protection, and logistics.

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Full-Service Dunnage & Assembly Tray Manufacturing


Dordan provides end-to-end manufacturing solutions for custom dunnage and assembly trays, combining in-house engineering, tooling, and thermoforming for total project control and rapid turnaround.

Our Capabilities Include:

Dordan's thermoforming machines

Above: Some of Dordan's plastic thermoforming machines for manufacturing custom dunnage trays

Custom Work-in-Process Trays for Industrial & Regulated Applications


Dordan has over 62-years of experience designing and thermoforming dunnage trays for a diverse range of industries:

Automotive & Transportation: We supply OEM's and Tier 1 suppliers with custom dunnage trays and assembly trays for robotic and manual part handling, returnable packaging systems, component staging for paint, coating, and assembly processes. Our trays are built for high-impact environments and are designed to stack, nest, and interface seamlessly with conveyor and automation systems.

Medical Device & Healthcare: Our ISO Class 8 cleanroom and ISO 13485:2016 certification allow us to produce medical WIP trays for device manufacturing and sterile assembly, cleanroom-to-cleanroom part transfers, component containment in surgical or procedural kits. We use medical-grade materials and validated manufacturing protocols to meet stringent cleanliness and regulatory requirements.

Electronics & Semiconductor: Dordan produces ESD-safe WIP trays and component carriers for PCB and semiconductor handling, Pick-and-place automation, static-sensitive part transport and staging. Available in dissipative and conductive materials, our trays protect delicate components from damage during storage and processing.

General Industrial & Automation: Our thermoformed dunnage and assembly trays improve efficiency, protection, and organization for aerospace and defense part handling, industrial machinery components, and injection molding and stamping operations. 

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Dunnage Tray Quality Assurance 


Dordan is certified to both ISO 9001:2015 and ISO 13485:2016, reflecting our commitment to continuous improvement, traceability, and regulatory alignment—whether you’re in automotive, medical, electronics, or industrial manufacturing.

Our Quality Management Capabilities Include:

  • First Article Inspection and Validation, In-Process Inspection: Every new tray design undergoes dimensional validation and first article inspection before entering full-scale production.

  • Statistical Process Control (SPC): Critical features are monitored in real-time using CPK (Process Capability Index) analysis to ensure tight tolerance adherence across production runs.

  • Automated Optical Inspection: For high-precision applications, Dordan uses vision-based inspection systems to validate part geometry, alignment, and repeatability without manual error.

  • Material & Lot Traceability: Each production run is supported by complete documentation—including raw material certifications, inspection data, and tooling specifications—ensuring full visibility from prototype to final delivery.

Cleanroom Manufacturing for Critical Applications


For industries where contamination is as important as precision, Dordan offers ISO Class 8 cleanroom thermoforming for work-in-process trays used in sterile, particulate-sensitive, and regulated environments.

Our cleanroom is designed for the controlled production of trays used in:

  • Medical device assembly and handling

  • Sterile barrier system packaging

  • Electronics and semiconductor processing

  • Cleanroom-to-cleanroom part transport

Dordan's cleanroom for manufacturing medical handling traysAbove: Dordan's cleanroom for manufacturing medical dunnage trays

Cleanroom Features & Capabilities

  • ISO Class 8 Certified Environment: Fully enclosed, hard-walled facility built to ISO 14644 air cleanliness standards—monitored for particle counts and environmental conditions.

  • Cleanroom-Ready Equipment & Tooling: Dedicated Keifel thermoformers with heated cutting dies and custom plug assists support precise forming with minimal particulate generation.

  • Contamination-Control Protocols: Separate gowning and material entry rooms, cascading airflow, and dry fog sanitation procedures help maintain ultra-clean production conditions.

  • Validated Manufacturing Processes: Cleanroom workflows are documented and maintained under our ISO 13485:2016 quality management system for medical-grade packaging compliance.

What Sets Dordan Apart


Full-Service Thermoforming Partner

Engineered for Automation & Repeatability

Cleanroom & Industrial Capabilities

Certified Quality & Traceability

4th-Generation Family-Owned Company Since 1962, Made in USA

Get a Quote for Custom Dunnage or Assembly Trays


Need high-performance thermoformed trays for WIP, assembly, or shipping? Request a Quote or Contact Us today to start your project.