01Overview

TRAYS & LINERS

Thermoformed Handling Trays & Liners

13 years of trays.Now heavy-gauge too.

Thermoformed Handling Trays & Liners 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.

Send drawings, answer in 2 working days See load and return

Illustration of a formed handling tray — Illustration: handling tray with pockets shaped to the part, stackable when loaded

Making formed trays since: 2013Electronics, new-energy and appliance customers
New-energy tray we've made: 2.5×1.1m4 mm sheet
Max. sheet for handling trays: 15mmParts up to 2600 × 1600 mm
DI-water wash room: Class 100Clean trays washed before delivery

02Range

Sizes and forms of heavy-gauge thermoformed trays and liners

Between processes,
and on the way to delivery.

01
Heavy-gauge handling trays
Heavy duty · stackable · reusable
8–15 mm sheet for heavier parts and long service; pockets locate the part, loaded trays stack and empty trays nest for the return trip.
02
In-box liners
For totes and racks
Drop into your existing totes or racks, with pockets that separate parts and stop knocks and mix-ups.
03
Precision clean trays
Thin gauge
Trays for electronic, semiconductor and optical parts, formed in our class 10,000 cleanroom and washed in DI water before delivery.

For small precision parts and clean trays, see thin-gauge thermoforming.

Three tray types, chosen by part size, weight and cleanliness:

Examples

Formed trays made by FUNYO
New-energy large tray, 2.5 m × 1.1 m
Formed tray for new-energy batteries
Formed tray for automotive parts
Formed tray for precision parts
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.

03Industries

Where thermoformed trays and liners are used

Applications
for this product.

Explore related industries through equipment applications and component requirements.

04Compare

Heavy-gauge thermoforming vs injection molding vs sheet metal

Beyond the price per tray,
cost the whole loop.

How three common options compare:

Send drawings, answer in 2 working days

	Heavy-gauge handling tray	Carton + foam	Injection-molded tote
Reuse	Many cycles; washable	Mostly single use	Reusable
Part location	Pockets shaped to the part	Cut foam; loose location	Generic cells; often needs a liner
Tooling	Low; about 1–3 weeks	None	High
Application	Low-to-mid volume, dedicated parts, returnable loops	Temporary or small shipments	High-volume standard parts

General comparison; we confirm against your parts, route and quantities.

05Stacking

Design options for thermoformed trays and liners

Stable when loaded.
Compact on the way back.

Loaded stacking, empty nesting and fit in the tote are designed and tested separately.

Schematic, not to scale

Loaded stackingLoad between layers

We define how load passes to the next layer, check clearances and run stack tests to the agreed height.

We have an anti-nesting tester and drop-test equipment, so sample trays can be tested first.

06Materials

Sheet materials for thermoformed trays and liners

Choose material by duty.
Prove performance by test.

“Black” or “thicker” doesn't define a tray. List load, contact surfaces, cleaning and ESD needs first, then pick the sheet.

Heavy-gauge thermoforming

Condition	Typical sheet
Heavy load, impact	HDPE or PP: tough and impact resistant for long service.
Stiffness and dimensional stability	ABS: stiff; suits trays that must locate parts precisely.
ESD protection	Static-dissipative grades; FUNYO has promoted permanent anti-static trays since 2014. Color is not proof of ESD performance; we verify by test method.
Clean delivery	Class 100 DI-water washing and laser particle counting; cleanliness criteria are agreed first.

Grade, sheet thickness and data sheets are confirmed per project; starting sheet thickness is not the formed wall thickness everywhere.

07Factory

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

FUNYO heavy-gauge thermoforming machine — 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 — 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 — Tunnel oven for secondary processing: adjustable temperature, airflow and conveyor speed

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

Tray-specific equipment

Tray washing line using DI water — DI-water tray washing line developed in-house

Anti-nesting tester: checks empty trays don't jam

Laser particle counter in use — Laser particle counter: checks cleanliness after washing

Selected long-term customers

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

08Delivery

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.

Heavy-gauge thermoforming CNC trimming and machining

FUNYO CNC machining shop — CNC shop: forming tools are machined in-house, so revisions don't wait on outside suppliers

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.

09Inquiry

Heavy-gauge thermoformed trays and liners: FAQ

Send the part
and the route it travels.

Part model or photos, the surfaces to protect, how it's picked and the tote it rides in, plus quantities, and we can start a sample tray.

FAQ

For 300–3,000 handling trays and liners per year, should I compare thermoforming and injection molding?

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 thermoformed handling trays and liners?

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.

How does thermoforming tooling cost compare with injection molds, and how many weeks does it 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.

Does moving CNC-cut openings for a new model require another forming tool?

If the external geometry, sheet and forming datums stay unchanged, we can evaluate a CNC program and fixture change. Changes to the formed shape require a separate tooling review.

Can medical or industrial housings meet a UL 94 or IP rating?

Provide the target rating first. Material grades are sourced and sampled per project; the housing, seals and assembly must be assessed together. Final ratings depend on testing the complete equipment.

Which sheet materials are available for housings and transparent windows?

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.

Can I receive a response in 4 hours, and when will thermoformed samples be ready?

We respond in 4 hours and provide an applicability assessment and injection-molding comparison quote in 2 working days. Forming tooling takes about 1–3 weeks; sample timing is assessed against the part geometry.

Can a housing project of about 3,000 parts per year apply for no tooling charge?

Housing projects of about 3,000 parts a year under an annual supply agreement can apply for an assessment. The quotation and contract define charges, amortization and tool ownership; eligibility is not automatic.

Last updated: 2026-10-22

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Thermoformed Handling Trays & Liners

Sizes and forms of heavy-gauge thermoformed trays and liners

Heavy-gauge handling trays

In-box liners