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.
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.
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.
NX CAD Packaging Design: Custom tray designs developed in-house using Siemens NX for optimal part fit, protection, and automation compatibility.
CNC-Machined Tooling: Precision-machined prototype and production tooling built on-site for faster development cycles and consistent quality.
Thermoforming: Use a wide range of materials, engineered for durability and reuse.
ISO Class 8 Cleanroom Manufacturing: Cleanroom production for trays used in sterile or particulate-sensitive environments.
ISO 9001:2015 and ISO 13485:2016 Certified Quality Management System
Above: Some of Dordan's plastic thermoforming machines for manufacturing custom dunnage trays
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.
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.
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.
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
Above: 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.
Full-Service Thermoforming Partner
Engineered for Automation & Repeatability
Cleanroom & Industrial Capabilities
Certified Quality & Traceability
4th-Generation Family-Owned Company Since 1962, Made in USA
Need high-performance thermoformed trays for WIP, assembly, or shipping? Request a Quote or Contact Us today to start your project.