Behind every consistent thermoformed part there is a controlled process. This article walks through sheet extrusion, heating, forming, trimming and the inspection steps that matter.
Everything here can be checked on a real sample before you commit to a production order.
This category covers a family of products rather than a single item. In practice a buyer defines industrial dunnage and handling trays by three things: the base resin, the format or dimension, and the performance or certification level it has to meet. Typical options in this category include ESD and conductive grades; custom cavity layouts; returnable and reusable designs. Materials most often specified are Polycarbonate, Polypropylene, Polyethylene Terephthalate, High Density Polyethylene, and the choice between them changes stiffness, temperature resistance, chemical behaviour and price.
In the logistics and warehousing sector the decision is usually driven by stackability and returnability, with traceability as a secondary requirement. Typical end uses include dunnage trays, bakey distribution crates, returnable trays.
Typical values for a general purpose grade are listed below; filled, stabilised and speciality compounds will differ.
| Material | Density | Tensile strength | Service temperature |
|---|---|---|---|
| Polypropylene | 0.90-0.91 g/cm³ | 25-40 MPa | -10°C to 100°C |
| Polyethylene Terephthalate | 1.35-1.40 g/cm³ | 50-70 MPa | -40°C to 70°C |
| Polycarbonate | 1.20 g/cm³ | 55-70 MPa | -40°C to 120°C |
Polypropylene is frequently the default selection here: PP is the lightest mainstream packaging resin and keeps its shape under repeated flexing.
Each step below has its own control points, and skipping one of them is where most defects start.
Critical control points are melt temperature, cooling time and the inspection of the first pieces of every shift. A stable process is documented with a parameter sheet that travels with the tool.
Beyond the base resin, most suppliers offer UV stabilised, food contact, flame retardant, anti-static and recycled content versions of the same product. Ask which additive package is included, because it is often the difference between a part that lasts three years and one that lasts ten.
Each step below has its own control points, and skipping one of them is where most defects start.
Secondary operations such as printing, welding, machining and assembly are often cheaper to do in the same factory, and they reduce the risk of mismatch between components.
These are the criteria that actually predict whether the part will perform in service.
Send this list to your supplier with the drawing and you will receive comparable quotations from every factory you contact.
Standard packing is export cartons on fumigation-free pallets, with custom labelling, barcode and retail packing available. We also handle consolidated containers and door to door delivery.
Yes. Standard samples are normally free of charge and shipped within three working days; custom samples are charged at cost and credited against the first production order.
Yes. {mat1} is one of our regular materials for this item, and we can supply virgin, modified and certified grades with full traceability. Material certificates and test reports are issued per batch.
A new tool typically takes 25 to 45 days depending on cavity count and complexity, followed by T1 samples within one week. Existing tools can usually start production within 10 to 15 days of order confirmation.
For standard sizes and colours the minimum is usually one pallet or one production run; for custom tooling the economic minimum depends on the tooling cost amortised over the expected volume. Send us your annual volume and we will calculate the break even point.
Share your specification and quantity with us and we will recommend the most cost effective material, tooling route and packing method for your market.
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