Common Defects in ABS Industrial Dunnage and Handling Trays for automotive and mobility and How to Prevent Them

Most quality claims on thermoformed parts trace back to a handful of root causes. Learn to recognise them on the drawing, in the tool and on the finished part.

This guide is written for engineers, purchasers and project managers who need a practical answer, not a resin data sheet.

Product Overview

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 custom cavity layouts; stack and nest geometry; ESD and conductive grades. Materials most often specified are Polyethylene Terephthalate, Polypropylene, Acrylonitrile Butadiene Styrene, Polycarbonate, and the choice between them changes stiffness, temperature resistance, chemical behaviour and price.

In the automotive and mobility sector the decision is usually driven by dimensional stability and heat resistance, with impact strength as a secondary requirement. Typical end uses include under body shields, dunnage trays, line side trays.

Key Material Properties

The table below summarises the values that usually decide the material choice.

Acrylonitrile Butadiene Styrene is frequently the default selection here: ABS is the default choice when a part needs a glossy, paintable, impact-resistant surface.

Failure Modes and Prevention

Spotting these early saves rework, freight and reputation.

• loss of stack stiffness – usually caused by material moisture; prevent it by controlling cycle parameters.
• warpage after washing – usually caused by melt temperature; prevent it by controlling resin drying.
• wear of locating features – usually caused by cooling rate; prevent it by controlling incoming inspection.
• static damage to parts – usually caused by material moisture; prevent it by controlling resin drying.
• cracking at low temperature – usually caused by tool wear; prevent it by controlling resin drying.

Common Grades and Variants

• High Density Polyethylene based: high impact strength even at low temperature
• Polyethylene Terephthalate based: excellent barrier to CO2 and moisture
• Polypropylene based: lowest density among commodity plastics
• Polycarbonate based: outstanding impact strength (250x glass)

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 and Finishing Options

The route below is the one most factories use for this type of part.

• Assembly
• Welding
• Thick gauge thermoforming
• Twin sheet forming

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.

How to Specify Industrial dunnage and handling trays Correctly

Use this checklist when comparing two or three supplier quotations.

1. validate washing and drying resistance
2. design locating features that survive repeated use
3. specify ESD grade if electronics are handled
4. check stack load and conveyor compatibility
5. define the number of returnable trips expected

Send this list to your supplier with the drawing and you will receive comparable quotations from every factory you contact.

Frequently Asked Questions

What packing and shipping options are available?

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.

What is the minimum order quantity for industrial dunnage and handling trays?

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.

How do you control colour consistency?

Colour is controlled with a masterbatch reference approved by the customer, and every production lot is checked against the approved sample under standard lighting before shipment.

Can you produce industrial dunnage and handling trays in Acrylonitrile Butadiene Styrene?

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.

Which certifications can you provide?

We can provide ISO 9001 quality system documentation, material certificates, RoHS and REACH statements, and where applicable food contact, flame retardancy or drinking water approvals. Tell us your target market and we will match the document set.

Conclusion

If you are planning a new automotive and mobility project, send us your drawing, annual volume and target properties, and we will come back with a material proposal, a tooling plan and a budget quotation.