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Thermoformed dunnage & assembly 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

Thermoformed trays engineered for production environments

Dunnage and assembly 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 manufacturing, handling, and transport.

  • 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 & assembly tray applications

Thermoformed tray applications across manufacturing and material handling

Dunnage and assembly 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

Thermoformed assembly 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 & assembly tray manufacturing

Design, tooling, thermoforming & quality control

Dordan supports dunnage and assembly tray programs in-house from initial design and engineering through tooling, thermoforming, and quality control.

Dunnage tray engineering drawing

Design & Engineering

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

CNC machine for dunnage tray tooling

Prototyping & Tooling

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

Thermoforming dunnage trays

Tray Thermoforming

Dunnage and assembly trays are thermoformed in-house to support repeatable production across a range of materials, gauges, and production volumes

Tray thermoforming quality control

Quality Control

Quality requirements are established for each application, with dimensional inspection, first article approval, and PPAP documentation available to support tight tolerances and customer-specific requirements

Start your dunnage or assembly tray project

Dordan provides custom design, tooling, and thermoforming for dunnage and assembly trays that protect, organize, and position parts throughout manufacturing.

Request a Quote Call (815) 334-0087