Thermoformed Dunnage & Assembly Trays

Family-owned dunnage tray manufacturer with 60-years experience of custom thermoforming.

Custom plastic dunnage trays are highly-engineered packaging solutions for product protection, assembly, and shipping. Designed for automated or manual parts assembly operations and problem free shipping, dunnage trays require tight form and die cutting tolerances be held to meet customers' quality requirements. 

further compressed esd handling enhanced-1


Dunnage Tray Benefits

Protect products and facilitate supply chain efficiences with thermoformed dunnage trays. 

  • Thermoformed dunnage trays can be designed to stack and rotate, which means that there is clearance between the top of the product and the bottom of the tray directly on top when stacked. This provides superior product protection during shipping and handling. 

  • Dunnage trays can also be designed for automated part assembly operations. Here, locators orient the thermoformed tray in the assembly module; and, guide robotics to the product for loading and/or unloading.

  • Locating features on the CNC-machined thermoform tooling mate with the cutting die to facilitate tight die cutting tolerances. 

  • Consistent material distribution, married with structural design features, are made possible with intelligent dunnage tray and tooling design and development; this provides the necessary rigidity and durability for material handing.

  • Dunnage trays can be made of recycled material; and, they can be designed for reusability.

  • ESD dunnage trays (electro-static discharge) dissipate the electrical charge from the thermoforming process; and, minimizes the attraction of particulate to the formed tray. 

TKD dunnage resized

Assembly Trays for Automated Parts Handling

Optimize cycle time, reduce waste, and improve QC with thermoformed assembly trays from Dordan.

Thermoformed assembly trays are used with automated equipment to protect and transport products and components throughout workstations or facilities. Pick and place, or other robotic mechanisms, load and unload parts from the assembly trays, facilitating operational efficiency gains and superior quality control. 

Thoughtfully engineered with a full understanding of the automation process, Dordan manufactures consistently high quality thermoformed assembly trays that integrate with existing, or in development, robotic platforms. 

Assembly Tray Features

  • Versatility of plastic and thermoforming process allows for the production of compact designs that accommodate the ideal number of parts per tray to meet shipping and assembly cycle-time goals.

  • Available materials for thin gauge assembly trays range in thickness from .020"-.120". Popular materials include RPET (clear) and RHIPS (black). ABS and low-moleculare-weight talc-filled PP are preferred for returnable trays.

  • Thermoformed assembly trays nest during shipment, saving on freight. At the same time, they denest easily for entry into the assembly cell via design features that mate with the equipment denesting mechanism.

  • Assembly trays can also be developed for shipping, utilizing stack and rotate features to create clearance between the products and tray above when stacked. This offers enhanced product protection during shipping and handling.

  • Trays for automation are designed with locators that assist the robot in locating the tray and locating the product in the tray cavities. Determining the design and placement of the locators on the tray is critical to the success of the automatic parts assembly operation.

  • Dordan's assembly trays are manufactured in America from recycled plastics. They can also be designed for reusability. 

  • ESD assembly trays (electro-static discharge) protect sensitive electronics and components from electric charge during the material handling process. 

Thermoformed dunnage tray resized

Dunnage & Assembly Tray Designer & Manufacturer

ISO 9001: 2015 certified dunnage tray supplier with in house design, tooling, & manufacturing.

  • Dordan is a full service thermoformer of plastic dunnage trays; the same team of packaging engineers that develop the solid model NX dunnage tray design also produce the NX CAM/CNC machined stainless steel tooling. This integration between design, tooling, and thermoforming allows for the manufacture of high quality dunnage trays in quick turnaround at competitive pricing.

  • Customer-specified critical tolerances are integrated into the dunnage tray design process at Dordan. Here, a multi-departmental workflow between engineering, quality control, and production ensures that dunnage tray tolerances are met during manufacturing.

  • Automated optical inspection equipment rapidly quantifies the dimensions and tolerances of the thermoformed dunnage trays.

  • Dordan is ISO 9001: 2015 certified with an ISO Class 8 cleanroom for manufacturing medical, electronic, and automotive handling trays that require monitored levels of particulate in the production environment.