Thermoformed Logistics Trays
Parts sit tight, grippers get in,empty trays nest.
Thermoformed Logistics Trays are shaped from heated plastic sheet. FUNYO forms single parts up to 2600 × 1600 × 600 mm from sheet up to 15 mm; housings commonly use 8–10 mm. Forming tools take about 1–3 weeks and cost under 1/10 of a comparable injection mold.
- Max. part size
- 2600×1600×600mmL × W × H, formed in one piece
- Max. sheet thickness
- 15mm8–10 mm is typical for housings
- Tooling lead time
- 1–3weeksvs. about 6–10 weeks for a comparable injection mold
- Tooling cost
- <1/10of a comparable injection mold
- 01Shaped pockets
- Pockets follow the part
- 02Automated picking
- Room for grippers
- 03Returnable loops
- Empty trays nest to save space
Thermoformed parts for packaging & material handling
Follow the part around the plant,
then design the tray.
Formed parts used in handling loops:
- Between processes
- Line-side supply
- Automated picking
- Returnable transport
- 01
Work-in-process trays
Pocketed to the part to prevent knocks; loaded trays stack.
- 02
Line-side supply trays
Parts face the same way, picked in order by people or robots.
- 03
Automated pick-and-place trays
Room for grippers, with tray locating edges matched to fixtures.
- 04
In-box liners
Fit your existing totes or racks, with a pocket per part.
Product families for this industry
Examples of thermoformed components
Examples:
formed parts you can see.
Formed parts from the FUNYO company profile, picked for this industry. Need something similar? Send a drawing or a photo.
Send drawings, answer in 2 working days
Formed trays made by FUNYO 
Battery separator tray for automated lines 
Formed tray for automotive parts 
Formed packaging tray, new energy 
Formed tray for precision parts 
Deep-drawn formed tray 
Protective insert for consumer goods 
Leak-proof medical pallet
Images from the FUNYO company profile. Some show the complete product; the formed part is the one named in the caption.
Thermoforming compared with other processes
Beyond the price per tray,
cost the whole loop.
When comparing tray options, fix the period and delivered quantity first, then look at:
Send drawings, answer in 2 working days| Item | What to include | Evidence |
|---|---|---|
| Initial investment | Tooling, trays, totes and in-transit quantity | Actual investment over the same period |
| Transport and return | Loaded quantity, empty volume, return frequency | Route and tote records |
| Washing and replacement | Washing, wear and scrap criteria | Trial and maintenance records |
| Part damage | Damage, rework and good parts delivered | Quality and delivery data |
Compare on the same basis and the tray decision matches the real route.
Assembly, access and interface design
The gap for the gripper
is part of the tray.
Beyond a snug pocket, the tray has to suit how the next process picks the part:
Support and keep-out
Mark where the part may be supported and where it must not be touched; support follows weight and center of gravity.
Needed: part model and weight
Fingers and grippers
Define where it's gripped and which way it's lifted, and leave room for fingers or gripper.
Needed: gripper shape and pick direction
Orientation and stacking
Pocket shape and orientation marks keep parts consistent; loaded stacking and empty nesting are tested separately.
Confirmed: stacking and anti-nesting tests
Sheet materials and project requirements
One tray,
two duty cycles: loaded and empty.
Heavy-gauge handling trays use 8–15 mm sheet; precision clean trays use thin gauge.
Heavy-gauge thermoforming| Heavy load, long service | HDPE or PP: tough and impact resistant. |
|---|---|
| Dimensional stability and location | ABS: stiff. |
| ESD protection | Static-dissipative grades; color is not proof, so we verify by test method. |
| Clean delivery | Class 100 DI-water washing and laser particle counting. |
Reuse count and load capacity are confirmed by testing sample trays.
Factory, CNC trimming and inspection
Forming, trimming, inspection:one plant in Zhuhai.
FUNYO started in precision machining in 2004 and has been thermoforming since 2013. Heavy-gauge forming, CNC trimming and dimensional inspection all happen in our Doumen plant, and we machine our own forming tools, so revisions don't wait on outside shops.
Facts you can check
- 2004
- Founded; 20+ years of precision machining
- 2005
- Became a tier-1 supplier to Gree
- ISO 9001 · 14001
- Quality and environmental management certified
- 2024
- Recognized as a High-Tech Enterprise
- ABS · PET/PS
- Own plant for thermoforming sheet
- 4 hours
- Response to design requests
Selected long-term customers
These relationships cover precision formed trays, CNC parts and other work. Listed in no particular order.
Lead time from drawing to delivery
From drawing to production,
and how long each step takes.
Typical timings. Complex parts or special materials get a specific schedule when we quote.
- Within 4 hours
Response
An engineer contacts you to confirm use, size and quantities.
- 2 working days
Evaluation and quote
We tell you whether heavy-gauge fits and quote it side by side with injection molding.
- About 1–3 weeks
Tooling
After design review we machine the forming tool in-house.
- By complexity
Samples
Formed, trimmed and drilled, then fitted to your frame or mating parts.
- Per order
Production
Checked against the approved sample for size and finish, then packed and shipped.
Thermoforming for packaging & material handling: FAQ
Bring the part,
and the route it travels.
Tell us how it's loaded, picked, stacked and returned. The clearer the route, the closer the evaluation is to real cost.
FAQ
Can thermoforming be evaluated for packaging & material handling at 300–3,000 units per year?
300–3,000 units is a quoting scenario, not a break-even threshold. Compare part size, assembly, material, tooling and unit costs before selecting a process.
What size and sheet thickness are available for packaging & material handling?
The maximum single part is 2600 × 1600 × 600 mm, with sheet up to 15 mm. Housings commonly use 8–10 mm sheet. Finished dimensions depend on geometry and trimming allowance.
Which sheet grades should I specify for packaging & material handling?
ABS, PC, PVC, PETG and PP can be formed. PC or PETG can be evaluated for transparent parts. PE, weatherable, flame-retardant and antistatic grades are sourced and sampled for the project.
How long does tooling for packaging & material handling take?
Forming tooling costs under 1/10 of a comparable injection mold and takes about 1–3 weeks. Comparable injection molds take about 6–10 weeks. Confirm the scope against the drawing and material.
What should I send for a 2-working-day thermoforming assessment for packaging & material handling?
Send drawings or photos, dimensions, annual and first-order quantities, assembly interfaces and operating conditions. We respond in 4 hours and provide the applicability assessment and comparison quote in 2 working days.
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