---
title: "Thermoformed Packaging, Handling Trays & Liners | FUNYO"
description: "Thermoformed parts for packaging and material handling. FUNYO provides 1–3 week tooling, sheet forming and CNC trimming to drawings."
type: landing
---

# 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**: 2600×1600×600 mm — L × W × H, formed in one piece
- **Max. sheet thickness**: 15 mm — 8–10 mm is typical for housings
- **Tooling lead time**: 1–3 weeks — vs. about 6–10 weeks for a comparable injection mold
- **Tooling cost**: \<1/10 — of a comparable injection mold

- **Shaped pockets**: Pockets follow the part
- **Automated picking**: Room for grippers
- **Returnable loops**: Empty trays nest to save space

## Thermoformed parts for packaging & material handling

Formed parts used in handling loops:

- Between processes
- Line-side supply
- Automated picking
- Returnable transport

### Work-in-process trays

Pocketed to the part to prevent knocks; loaded trays stack.

### Line-side supply trays

Parts face the same way, picked in order by people or robots.

### Automated pick-and-place trays

Room for grippers, with tray locating edges matched to fixtures.

### In-box liners

Fit your existing totes or racks, with a pocket per part.

### Product families for this industry

#### [Trays & liners](/en/products/trays-liners)

Work-in-process, line-side supply and automated pick-and-place trays.

### Small precision parts or clean trays?

Thin-gauge thermoforming: formed in our cleanroom, up to 120 mm deep, washed in DI water before delivery.

[Thin-gauge precision trays](/en/capabilities/thin-gauge-thermoforming)

## Examples of thermoformed components

Formed parts from the FUNYO company profile, picked for this industry. Need something similar? Send a drawing or a photo.

![Formed trays made by FUNYO](/assets/thin-gauge/trays.webp)

Formed trays made by FUNYO

![Battery separator tray for automated lines](/assets/ppt/battery-separator-tray.webp)

Battery separator tray for automated lines

![Formed tray for automotive parts](/assets/ppt/auto-parts-tray.webp)

Formed tray for automotive parts

![Formed packaging tray, new energy](/assets/ppt/energy-packaging-tray.webp)

Formed packaging tray, new energy

![Formed tray for precision parts](/assets/ppt/precision-parts-tray.webp)

Formed tray for precision parts

![Deep-drawn formed tray](/assets/cases/deep-tray.webp)

Deep-drawn formed tray

![Protective insert for consumer goods](/assets/cases/consumer-insert.webp)

Protective insert for consumer goods

![Leak-proof medical pallet](/assets/ppt/leakproof-pallet.webp)

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

When comparing tray options, fix the period and delivered quantity first, then look at:

| 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

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

Heavy-gauge handling trays use 8–15 mm sheet; precision clean trays use thin gauge.

- **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

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.

![FUNYO heavy-gauge thermoforming machine](/assets/factory/heavy-forming.webp)

Heavy-gauge former: ABS, PC, PVC, PETG and PP sheet; parts up to 2600 × 1600 × 600 mm

![FUNYO 3-axis and 5-axis CNC routers with a formed part on the bed](/assets/factory/cnc-router.webp)

3- and 5-axis CNC routers: trimming, holes and slots after forming; 5-axis for curved surfaces

![Tunnel oven in FUNYO's secondary-processing area](/assets/factory/tunnel-oven.webp)

Tunnel oven for secondary processing: adjustable temperature, airflow and conveyor speed

![Engineer measuring a part on a vision measuring system](/assets/thin-gauge/cmm.webp)

Vision measuring system checks holes and contours; a 3D automatic vision system is also on site

### 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

Gree Electric, Panasonic, Foxconn, Jabil, Lite-On, TDK, Mitsumi Electric, Mektec, Broad-Ocean Motor, Haojue, JCD, AKM, CYGIA

These relationships cover precision formed trays, CNC parts and other work. Listed in no particular order.

## Lead time from drawing to delivery

Typical timings. Complex parts or special materials get a specific schedule when we quote.

1. **Within 4 hours · Response**: An engineer contacts you to confirm use, size and quantities.
2. **2 working days · Evaluation and quote**: We tell you whether heavy-gauge fits and quote it side by side with injection molding.
3. **About 1–3 weeks · Tooling**: After design review we machine the forming tool in-house.
4. **By complexity · Samples**: Formed, trimmed and drilled, then fitted to your frame or mating parts.
5. **Per order · Production**: Checked against the approved sample for size and finish, then packed and shipped.

[Heavy-gauge thermoforming](/en/capabilities/heavy-gauge-thermoforming) · [CNC trimming and machining](/en/capabilities/cnc-machining-trimming)

## Thermoforming for packaging & material handling: FAQ

Tell us how it's loaded, picked, stacked and returned. The clearer the route, the closer the evaluation is to real cost.

**Send a drawing. Get an answer in 2 working days.** We respond within 4 hours. Within 2 working days we tell you whether heavy-gauge thermoforming fits, with a side-by-side quote against injection molding. Housing projects of around 3,000 parts a year on an annual supply agreement can apply for a no-tooling-charge evaluation.

- Equipment and part: e.g. motor-housing work-in-process trays
- Outside dimensions: L × W × H (mm)
- Trays needed and parts per tray: e.g. 500 trays, 12 parts each
- Handling and loop: Manual or robot, stack height, washing, ESD needs
- Contact: Name, company, phone or email

Send drawings or photos to fangyujidian@163.com

STEP, IGES, DWG, PDF or photos. No drawing yet? Send photos and key dimensions.

### 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.

### Guides

- [Large Thermoformed Handling Trays: Specification](/en/guides/large-thermoformed-handling-trays)
- [Thermoformed Automation Trays: Tolerances and ESD](/en/guides/automation-tray-tolerance-stacking-esd)
- [Thin-Gauge vs Heavy-Gauge Thermoforming for Parts](/en/guides/thin-gauge-vs-heavy-gauge-thermoforming)

## Contact

Bring us your next big idea. Let’s give it the right shape.

FUNYO / 方宇机电

Building F3, Huamao Road, Qianwu Town, Doumen District, Zhuhai, Guangdong, China

Tel: +86-0756-6330998

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Last updated: 2026-10-22