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

Dordan Manufacturing is a family-owned dunnage tray designer and manufacturer with over 63 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.

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.

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:

• 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

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.