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Custom thermoformed dunnage trays

Thermoformed trays designed to organize, protect, and position parts throughout manufacturing, assembly, and shipping operations

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Custom thermoformed dunnage tray
Thermoformed dunnage tray

Custom dunnage trays engineered for production environments

Dunnage tray systems are developed around part dimensions, stackability, material selection, and handling requirements to support product protection, orientation control, and efficient material flow through production.

Designs are evaluated for functionality, automation compatibility, shipping requirements, and long-term durability to support consistent performance throughout the supply chain.

  • Custom thermoformed trays developed around product geometry
  • Stackable designs for storage and transport efficiency
  • Automation-compatible handling and orientation features
  • Anti-stat, ESD, and conductive material options

Dunnage tray applications

Dunnage tray applications across manufacturing and material handling

Dunnage trays are used across assembly, work-in-process handling, inspection, shipping, and reusable or returnable packaging programs. Each tray format is developed around how the part is stored, moved, and presented throughout the manufacturing process.

Thermoformed assembly tray

Automated Assembly & Handling

Used in automated manufacturing environments where parts need to remain consistently positioned for robotic loading, operator access, and repeatable handling

Work in process handling tray

Work-in-Process Handling

Used between production steps to organize, protect, and transport components while maintaining orientation and presentation

Shipping and returnable thermoformed packaging

Shipping & Returnable Packaging

Used to protect products during storage and transport, including reusable and returnable packaging programs

Built for controlled part flow

Dunnage tray systems help maintain component position, reduce part-to-part contact, and support consistent handling from staging through production and transport.

  • Controlled part orientation for operators, inspection, and automation
  • Consistent presentation between process steps
  • Organized staging and material flow throughout production
  • Disposable, reusable, and returnable tray options
Automation at Dordan

Dunnage tray design & manufacturing

Design, tooling, and manufacturing under one roof

Cross-functional teams support dunnage tray programs from engineering review through production launch.

Dunnage tray engineering drawing

Design & Engineering

Dunnage tray layouts are developed around part geometry, orientation, stackability, automation, handling, and line-side presentation requirements

CNC machine for dunnage tray tooling

In-House Tooling Development

Prototype and production tooling is CNC-machined in-house to support cavity accuracy, part fit, repeatability, and efficient design revisions

Thermoforming dunnage trays

Thermoforming & Quality Control

Dunnage trays are thermoformed under ISO-certified production controls to support dimensional consistency, material performance, and repeatable manufacturing

Custom dunnage and assembly trays

Dordan designs and manufactures thermoformed trays for part handling, assembly operations, work-in-process storage, and product transportation throughout manufacturing environments.