Electronics Packaging Thermoforming | ESD Dunnage Trays, Clamshells & Blisters

Dordan specializes in thermoformed electronics packaging for electrostatic-sensitive devices and components. With over 62 years of experience, we deliver precision-engineered ESD packaging solutions that protect electronic products from manufacturing to end use.

What Is Thermoformed Electronics Packaging?

Thermoformed electronics packaging refers to custom plastic trays, blisters, clamshells, and inserts engineered to protect, organize, display, and transport electronic components. Used in both consumer and industrial markets, these thermoformed plastic solutions are tailored to the shape and function of each part, providing reliable protection throughout the supply chain.

Industrial Electronics Applications

• ESD-Safe Trays: Protect electrostatic-sensitive devices like circuit boards and semiconductors from static discharge.

• Dunnage/Work-in-Process/Shipping/Assembly Trays

  • Facilitate efficient handling and organization of parts on assembly lines.

  • Designed for seamless integration with robotic systems and automated equipment.
    

  • Durable trays for repeated use in closed-loop logistics, reducing waste and cost.

Consumer Electronics Applications

• Clamshell Packaging: Clear, tamper-evident enclosures that showcase products like headphones and accessories.

• Blister Packs: Secure packaging for items such as batteries and small gadgets, combining visibility with protection

• Custom Inserts: Tailored trays that hold products securely within retail boxes, improving unboxing experience.

• ESD packaging for sensitive consumer electronics 

Cleanroom Electronics Packaging

• Made in a complete hard-wall and fully enclosed ISO Class 8 cleanroom

• Reduces airborne particulate for high-precision components

• Suitable for medical electronics, optical sensors, and microdevices

In-House Design, Tooling & Thermoforming for Electronics Packaging

At Dordan Manufacturing, we provide fully integrated packaging development—delivering speed, precision, and control from concept to production. By offering all core services under one roof, we eliminate delays, reduce costs, and ensure quality at every stage.

Our In-House Capabilities Include:

• Custom Package Design: Our engineering team works directly with customers to design trays, clamshells, and inserts that meet the specific needs of electronic components—from size and weight to fragility and ESD sensitivity. We use CAD software, 3D printing, an rototyping for fast, accurate prototyping and design validation.

• Tooling Fabrication: All production tooling is machined in-house using CNC equipment. This gives us tighter control over lead times, tolerances, and revisions—allowing faster iterations and higher quality final parts.

• Thermoforming: We thermoform your packaging in our ISO 9001:2015 and ISO 13485:2016 certified facility using a wide range of materials, including ESD-safe plastics, PETG, HIPS, and conductive options. Whether for one-time use or reusable/returnable applications, we produce parts to exacting standards.

• Validation & Quality Control: Our quality assurance process includes dimensional verification, fit testing, and—if required—full process validations to support highly regulated industries like medical and industrial electronics.

• Cleanroom Manufacturing: We produce packaging for sensitive electronics and components in our ISO Class 8 cleanroom.

Quality Assurance for Electronics Packaging

When packaging sensitive electronic components, quality isn’t optional—it’s essential. At Dordan, we operate under an ISO 9001:2015 and ISO 13485:2016 certified Quality Management System, ensuring every thermoformed part meets your exact specifications for fit, function, and reliability.

Our Quality Process Includes:

• Dimensional Accuracy & Repeatability.

• Material Verification

• In-Process & Final Inspections: 

• Documentation & Traceability

• Cleanroom Manufacturing

• Automated Optical Inspection

• Risk-Based Engineering

Why Choose Dordan?

Fully In-House Operations