Dordan is a leading U.S.-based manufacturer of custom thermoformed automotive packaging, including dunnage trays, work-in-process (WIP) trays, shipping trays, and assembly trays. We support global automotive OEMs and their supply chain partners with high-performance tray solutions designed for protection, automation compatibility, and cost-effective logistics.
In the automotive industry, precision, protection, and process efficiency are critical. Thermoformed dunnage trays are engineered packaging solutions designed to safely transport and organize components—such as fasteners, gears, clips, housings, and assemblies—throughout your supply chain.
These custom plastic trays are molded to the exact geometry of each part, minimizing damage, improving handling, and supporting lean manufacturing initiatives across production and distribution environments.
Part Protection in Transit and Assembly: Trays isolate components during movement and storage, preventing scuffs, breakage, and contamination—especially for Class A surfaces or sensitive geometries.
Process Optimization: Designed for compatibility with automation and robotic handling systems, dunnage trays increase throughput and reduce manual handling errors.
Reusable, Returnable, and Cost-Efficient: Durable materials allow for repeated use in closed-loop systems, helping OEMs and Tier suppliers reduce packaging waste and meet sustainability goals.
Space-Efficient Design: Stackable and nestable features improve logistics efficiency and optimize warehouse and trailer space.
Material Versatility: From standard HIPS to static-dissipative and high-impact polymers, material selection is tailored to the part type, environmental exposure, and handling method.
Dordan’s Automotive Trays Include:
WIP trays for internal handling and part staging
Assembly trays with locating features for robotic or manual systems
Shipping trays engineered for secure transport in cartons, totes, and racks
ESD-safe trays made with anti-static, electro-static dissipative, and conductive materials
All trays are designed and produced in-house, with integrated NX CAD design and NX CAD CNC tooling, for exceptional quality and consistency.
Above: Some of Dordan's thermoforming machines for manufacturing automotive trays and packaging
In the automotive industry, timing, precision, and performance are everything. At Dordan, we support your production goals with packaging services engineered specifically for automotive workflows. From launch through production, our team delivers thermoformed solutions that integrate seamlessly into your process—on time and on spec.
Application-Specific Tray Design: Whether it’s for stamping, injection molding, or assembly, we develop packaging around how your parts are made and moved. Our design approach considers automation compatibility, material handling, part orientation, and protection—ensuring trays that work as hard as your team.
Dedicated Automotive Tooling: Our in-house tool shop builds custom thermoform tooling to meet your program’s unique requirements. With tight tolerances, material-specific design, and quick-turn adjustments, we ensure production readiness without delays.
High-Performance Thermoforming: Dordan manufactures reusable dunnage trays and part organizers using robust materials suited for industrial environments. Each tray is built for structural integrity, stackability, and long-term performance in closed-loop systems.
Production Support & Validation: We assist with sample submissions, dimensional reports, and quality documentation—including PPAPs, capability studies, and traceability—as required by your customer or program.
Cleanroom Thermoforming: For automotive products and components that are sensitive to particulate
Robot strips tray from plastic web after die cutting before inspection and packing
At Dordan Manufacturing, our ISO 9001:2015 and ISO 13485:2016 certified Quality Management System is built to support the stringent demands of automotive OEMs and Tier suppliers, from prototype through production.
Production Part Approval Process (PPAPs): We support full PPAP submissions—including dimensional results, material certifications, control plans, and process flow diagrams—to help you meet customer-specific requirements and ensure product conformity.
Process Capability Studies (CPK/PPK): Our team performs process capability analysis to verify that parts meet statistical standards for performance and repeatability. We strive for a CPK of 1.33 or higher where required.
First Article & In-Process Inspections: Every project begins with dimensional verification and fit testing, followed by routine inspections throughout production to ensure tight tolerances and consistent quality.
Validated Tooling & Manufacturing: In-house tooling allows us to maintain control over critical dimensions and implement corrective actions quickly if needed. Our thermoforming processes are tightly monitored for stability and accuracy.
Traceability & Documentation: All materials, processes, and inspections are documented to support quality audits and regulatory compliance.
Cleanroom Thermoforming: For automotive products and components that are sensitive to particulate
From dunnage trays to assembly aids, our quality systems are designed to ensure that your packaging solutions meet both functional and regulatory requirements—delivering peace of mind with every shipment.
We manufacture automotive clamshells, bifolds, and blisters for retail display and eCommerce fulfillment:
Tamper-resistant and damage-resistant for in-store security
Easy to load and ship — no sealing equipment needed
ESD-safe options available for electronic accessories
Available in 100% recycled and recyclable materials
Ideal for automotive accessories, aftermarket parts, and tools
What Sets Dordan Apart:
Fourth-Generation, Family-Owned Company, Made in USA Since 1962
Comprehensive In-House Services
ISO-Certified Quality Systems
Custom Engineered Solutions
Material Versatility
Sustainable & Returnable Packaging Options
Whether you’re looking for durable dunnage trays, automation-compatible assembly trays, or recyclable retail clamshells, Dordan delivers custom thermoformed packaging tailored to your production and supply chain requirements. Request a Quote or Contact Our Team today.