Custom Thermoformed Packaging Solutions
Custom thermoformed packaging developed around your product, protection requirements and production needs—from initial structure review to sampling and repeatable volume production.
Find the Right Thermoformed Packaging for Your Application
protected, handled, transported or displayed.
Retail Display and Sealed Packaging
Thermoforming blister packaging and clamshells are designed for products that need visibility, retail presentation and secure enclosure. The right format depends on how the product will be displayed, opened and protected throughout distribution.
Product Trays and Protective Inserts
Custom thermoformed trays and protective inserts hold products in position, separate components and reduce movement during packing, storage and transport. The cavity structure can also be developed to fit an outer carton or presentation box.
Industrial Handling and Reusable Packaging
Industrial thermoformed trays and heavy-gauge parts support component handling, stacking, storage and repeat production use. Projects may also need to consider operator access, returnable use, denesting or compatibility with automated equipment.
Start with Your Product Requirements
Start with your product, drawings or existing packaging. We develop the tray structure around how the product needs to be protected, handled and packed.
Product Fit and Protection
Product shape, weight, fragile areas and surface condition affect how the cavity should support and retain the product. The structure should limit movement without creating pressure points or making the product difficult to remove.
Handling and Packaging Conditions
Tray design also depends on what happens after the product is loaded. Stacking, nesting, operator access, outer-box dimensions and automated handling may all change the cavity layout and tray structure.
Material and Performance Requirements
Material and thickness should be selected according to the required strength, clarity, surface protection and operating environment. Special requirements such as ESD control, food contact or repeated use should be identified before sampling.
Drawings can be reviewed within 1–2 days
with engineering support available for structure and material development.
Develop the Insert and Outer Packaging Together
Thermoformed inserts and paper packaging can be reviewed as one system to improve dimensional fit and reduce coordination between separate suppliers.
Dimensional Coordination
The insert dimensions, box interior space and product position can be checked together.
Fewer Supplier Handoffs
Changes can be coordinated without repeatedly transferring drawings and samples between separate suppliers.
Review the Sample Before Full Production
Samples are reviewed before production to confirm the structure,
prepare the forming setup and check consistency during manufacturing.
Sample Review
Approved samples are checked against product requirements before production release.
Forming Setup
Tooling and machine settings are prepared based on the approved structure and material requirements.
Production Consistency
Production output is monitored to maintain stable quality across manufacturing batches.
Initial samples can typically be prepared in approximately 3–4 days for suitable projects.
Built for Repeatable Production
Sample approval is only the first step. Production must maintain the same fit, quality and performance for every batch.
Consistent Fit and Dimensions
The approved tray structure is maintained during production to ensure reliable product positioning and packaging performance.
- Cavity structure and product positioning
- Key dimensions and critical features
- Stacking stability and external fit
- Batch-to-batch consistency
Controlled Forming and Trimming
Stable forming conditions and trimming control help maintain the appearance and function expected from approved samples.
- Consistent forming conditions
- Material distribution control
- Clean trimming and edge quality
- Reduced variation between batches
Reliable Production Capacity
Manufacturing experience and production resources support repeat orders and long-term supply requirements.
- 19+ years of thermoforming experience
- 31 production lines
- 30+ tons daily production capacity
- Support for repeat and long-term orders
Plan Your Volume, Tooling and Lead Time
Confirming volume, tooling and product details early helps establish a realistic quotation and delivery plan.
Order Volume
Standard order quantities differ between thin-gauge packaging and heavy-gauge thermoforming.
Final production planning may vary with product size, material and project requirements.
Custom Tooling for Every Project
Each project requires custom tooling. Mold selection and cost depend mainly on product dimensions, required precision and mold material.
Tooling Board Mold
A cost-effective option for projects without demanding dimensional accuracy or tight product-fit requirements.
- Lowest tooling investment
- Suitable for basic structures
- Not recommended for high-precision applications
Copper Mold
A middle-range option that provides better precision than tooling board while controlling tooling investment.
- Moderate tooling cost
- Improved forming accuracy
- Suitable for projects requiring balanced performance
Aluminum Mold
The preferred option for products requiring accurate fit, dimensional consistency and higher-end finished quality.
- Highest tooling investment
- Best dimensional precision
- Suitable for demanding or premium applications
Project Timing
Project timing includes tooling design, mold preparation, sample approval and volume production.
Tooling Drawing
The tooling design is prepared for review.
Simple Mold Completion
Simple tooling may be completed around the third day.
Sample Trial Fitting
Product fit, structure and load-bearing performance are checked.
Volume Production
Production timing after approval depends on order quantity.
Rush production may be available, but product trial fitting cannot be skipped. Complex tooling may also require additional preparation time.
What We Need to Prepare Your Quotation
The information required depends on whether an existing packaging sample is available.
You Have an Existing Packaging Sample
Send the original sample when possible. We can evaluate its material, thickness and weight before preparing the quotation.
- Original packaging sample
- Required order quantity
- Packing and delivery requirements
You Cannot Send the Sample
Provide the available specifications so the project can be evaluated without the physical packaging sample.
- Outer dimensions
- Material
- Thickness or weight
- Order quantity
- Packing requirements
- Preferred delivery method
This Is Your First Thermoformed Packaging Project
Send the actual product sample. We can develop the product layout and tray structure, then recommend suitable material and dimensions based on the application.
- Actual product sample
- Product use and handling conditions
- Packing and shipping requirements
- Expected order quantity
Thermoformed Packaging FAQs
Common questions about custom tooling, samples and production.
Can you recommend the right material for my application?
Yes. We recommend the material, thickness and structure based on the product, required protection, appearance, handling conditions and packaging process.
Does every custom project require a new mold?
Yes. Each project requires custom tooling because the tray structure and dimensions are developed around the actual product. Tooling board, copper and aluminum molds are available for different precision and budget requirements.
What if I do not have an existing packaging design?
Send us the actual product sample together with its packing, handling and shipping requirements. We can develop the product arrangement, tray structure, material and dimensions.
Can you test the tray with my product before production?
Yes. Trial fitting is a required step. We check product positioning, structural fit and relevant load-bearing requirements before the sample is approved for volume production.
What are your minimum order quantities?
The standard MOQ is 5,000 pieces for thin-gauge thermoformed packaging and 500 pieces for heavy-gauge thermoforming.
How long does tooling and production take?
Tooling drawings are normally prepared within 1–2 days. Simple tooling may be completed around the third day. After sample approval, volume production normally takes approximately 3–10 days, depending on quantity and production requirements.
Tell Us About Your Packaging Project
Share your product, quantity and packaging requirements. Our team will review the project and recommend the next step.