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.
This guide is written for engineers, purchasers and project managers who need a practical answer, not a resin data sheet.
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 returnable and reusable designs; custom cavity layouts; ESD and conductive grades. Materials most often specified are Acrylonitrile Butadiene Styrene, 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 parts supermarket trays, bakey distribution crates, picking trays.
The table below summarises the values that usually decide the material choice.
| Material | Density | Tensile strength | Service temperature |
|---|---|---|---|
| Acrylonitrile Butadiene Styrene | 1.04-1.06 g/cm³ | 30-50 MPa | -20°C to 80°C |
| Polypropylene | 0.90-0.91 g/cm³ | 25-40 MPa | -10°C to 100°C |
| Polycarbonate | 1.20 g/cm³ | 55-70 MPa | -40°C to 120°C |
Polycarbonate is frequently the default selection here: PC replaces glass where impact safety matters, but it needs a hard coat for abrasion resistance.
Processing method drives both cost and performance, so it should be fixed early in the design.
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.
Processing method drives both cost and performance, so it should be fixed early in the design.
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.
Use this checklist when comparing two or three supplier quotations.
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.
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.
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.
Standard production tolerance follows the relevant ISO or DIN tolerance class for the process; tighter tolerances are possible after machining or grinding, but they add cost. Define the tolerance only on the functional dimensions.
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.
Our team supplies industrial dunnage and handling trays to logistics and warehousing customers worldwide, with samples, material certificates and full inspection reports available before mass production.
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