Thermoformed Tray Design & Development

Five stages, with a typical timeline for each

Discovery
We gather details on the part, volume, life cycle, use, and requirements in an on-site visit or technical meeting.
Timeline: typically as soon as you're available, in person or online.
Concept
3D design with your part already positioned, plus a rendered image for approval.
Timeline: typically five days.
Prototype
A physical sample, typically of a single cavity, to validate fit and handling.
The cavity can be 3D printed.
Timeline: after your initial approval.
Validation
A pilot run, tested in your operation. The production mold is released only after you approve it.
Lead time: the pilot run is typically delivered five days after drawing approval.
Production
Volume production with in-house tooling, inspection, and lot traceability.
Lead time: 12 days after pilot run approval.

THE DESIGN ACCOUNTS FOR

GeometryHandlingESD protectionStackingTransportAutomation

A CLOSER LOOK

You see the tray with your part in place before the mold is built, so adjustments can be made at the design stage, which reduces rework and cost.

In-house tooling, the foundation of repeatability
CNC machining, high-polish aluminum molds, and trim dies made in-house, with a maintenance plan. That keeps the fit consistent lot after lot.
Well-distributed wall thickness, including at the corners
In thermoforming, the sheet stretches and thins at the corners. Controlling that thickness, so the tray is strong throughout and not just where the part touches, is one of the things that sets Termotray apart.
Have an existing mold? We'll assess whether it can be reused
Reusing your current mold can reduce your upfront investment.
Every part goes through revisions
When your part changes, we update the tray design from the existing file instead of starting from scratch.

We accept STEP, IGES, or PDF files. Development starts with the discovery stage.