Custom Thermoformed Trays Manufacturer | Medical · ESD · Food-Grade | DitaiPlastic

Custom Thermoformed Trays Manufacturer | Heavy-Gauge & Medical-Grade

Custom thermoformed trays from $200 prototype tooling. ESD-safe, antimicrobial, FDA-grade options. Up to 5000mm × 2500mm × 1000mm. Mutual NDA before drawing review.

We’ve been producing custom thermoformed trays for medical device packaging, electronic component handling, food-contact applications, and industrial parts protection since 1997. Our 16 vacuum forming machines run 24/7 to support startups (200 units/year) all the way to OEMs running 50,000+ trays/year.

What Trays We Manufacture

• Medical device trays — IVD analyzer cartridges, sterile-pack inserts, instrument trolley trays. USP Class VI ABS / PETG, ISO 13485 documented.
• Electronic component trays — JEDEC trays, ESD-safe carriers for PCBs/wafers/dies, antistatic ABS
• Food-contact trays — FDA-compliant PP / HDPE, agricultural seed propagation trays, hydroponic grow trays
• Industrial parts trays — Custom inserts for automotive parts handling, robotic assembly fixtures, kitting trays
• Battery transport pallets — Heavy-gauge HDPE, EV battery cell carriers, recycled-PP option
• Pet/animal industry trays — Grooming trays, cage bottoms, veterinary instrument trays
• Retail display trays — POP counter trays, brand-Pantone matched, Class A acid-etched finish

Why Thermoforming for Custom Trays vs Injection Molding

Factor	Thermoforming (us)	Injection Molding
Tooling cost	$200-$15,000	$25,000-$80,000
Tool lead time	3-7 days (MDF) or 2-3 weeks (aluminum)	8-14 weeks
Min volume	1 piece	1,000+ pieces typical
Max single-piece size	5000 × 2500 × 1000 mm	~600 × 400 × 200 mm typical
Material change	Sheet swap, no tool change	Often new tool required
Per-piece price (5K/yr)	$3-15 typical	$1-5 (after $50K tooling amortizes)

Verdict: Volumes under 5,000/year, large parts (>500mm), or fast iteration cycles → thermoforming wins decisively. We help you decide via free DFM review.

Specs That Matter for Trays

Capability	Value
Maximum tray size	5000 × 2500 × 1000 mm (single piece)
Sheet thickness	0.5 – 12 mm typical
Tolerance (CTQ dimensions)	±0.3 mm
Wall thickness uniformity	±10-15% with plug-assist
Surface finish	Class A acid-etched textured aluminum tools
Materials	ABS, PP, HDPE, PETG, HIPS, ASA, PC, PMMA — 8 grades extruded in-house
Specialty options	USP Class VI, antimicrobial silver-ion, ESD-safe, FR-grade UL94 V-0, FDA-compliant
Secondary operations	5-axis CNC trimming, drilling, foam inserts, ultrasonic welding, sub-assembly

Real Tray Production Cases

Case: 4,000/year medication cart panels (EU medical OEM)

• Material: silver-ion antimicrobial ABS
• Tray sub-units: 6 SKUs nested in cart
• Tooling: $11,200 total, 6 aluminum tools
• First-pass yield: 99.2%
• Compliance: ISO 22196 antimicrobial efficacy data passed through

Case: 12,000/year hydroponic seed propagation trays (AgTech startup)

• Material: food-safe PP, recyclable
• Tray dimensions: 600 × 400 × 60 mm
• Drainage hole pattern: 96 holes, 5mm diameter, ±0.2mm spacing
• Tooling: $4,800 single block-aluminum tool
• Per-piece: $2.40 at 12K/year
• Currently delivering 2-year contract

Case: ESD-safe JEDEC trays for semiconductor handling (Asia-Pacific OEM)

• Material: antistatic black ABS, surface resistivity 10^6-10^9 Ω/□
• Tray pocket count: 96 pockets for SOIC packages
• Tooling: $7,500
• Volume: 25,000/year on 3-year contract
• Quality: 100% optical inspection of pocket dimensions, ±0.1mm

What You Should Send for a Custom Tray Quote

• 3D CAD file (STEP, IGS, STP preferred; PDF / 2D drawing also acceptable)
• Material requirement (or describe environment: indoor/outdoor, food-contact, ESD, sterilizable, etc.)
• Annual volume estimate (1 piece is fine for prototype)
• Color / surface finish requirement (Pantone code if matching brand)
• Compliance requirements (FDA, USP Class VI, ISO 13485, UL94, etc.)

We respond within 48 hours with: feasibility, recommended material grade, tooling cost, per-piece price tiered by volume, lead time, and compliance documentation outline.

Frequently Asked Questions

Can you make trays with very tight pocket tolerances?

Yes — our JEDEC-spec trays achieve ±0.1mm on pocket dimensions via pressure-formed plug-assist tooling. Standard thermoforming tolerance is ±0.3-0.5mm; tighter than that requires specialty tooling and pressure forming (we offer both).

Do you offer ESD-safe / antistatic tray materials?

Yes. ESD-safe ABS (10^6-10^9 Ω/□), conductive ABS (10^3-10^6 Ω/□), and antistatic PP available. Surface resistivity verified per ANSI/ESD STM11.11 on every production batch.

Are your food-contact trays FDA-compliant?

Yes. Food-grade PP and HDPE compliant with FDA 21 CFR 177.1520. Material certificates of analysis (COA) provided on every shipment.

What’s the smallest order quantity for trays?

1 piece for prototypes (MDF tooling from $200). For production runs we typically suggest 50-500 units minimum for cost efficiency. Above that, per-piece price scales linearly up to 50,000+/year.

Do you provide ISO 22196 antimicrobial efficacy data?

Yes — when using silver-ion infused antimicrobial materials, we pass through ISO 22196 efficacy reports from the material supplier. Independent testing arrangeable on request.

Can you nest trays for shipping efficiency?

Yes — our DFM review specifically checks nesting geometry. Properly designed trays nest 8-15 deep in standard shipping cartons, reducing freight cost by 60%+ vs flat-shipped.

Get a Custom Tray Quote

Send drawing under NDA. 48-hour response with feasibility, material recommendation, tooling cost, per-piece price tiered by volume, lead time, and compliance documentation.

Contact: [email protected] | WhatsApp +86 138 2578 0422