--- title: "Thermoformed Trays & Liners for Parts Handling | FUNYO" description: "Thermoformed handling trays and liners up to 2600 × 1600 × 600 mm. Tooling takes 1–3 weeks; FUNYO forms and CNC-trims parts in Zhuhai." type: landing --- # 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. ![Illustration of a formed handling tray](/images/trays/hero.webp) Illustration: handling tray with pockets shaped to the part, stackable when loaded - **Making formed trays since**: 2013 — Electronics, new-energy and appliance customers - **New-energy tray we've made**: 2.5×1.1 m — 4 mm sheet - **Max. sheet for handling trays**: 15 mm — Parts up to 2600 × 1600 mm - **DI-water wash room**: Class 100 — Clean trays washed before delivery ## Sizes and forms of heavy-gauge thermoformed trays and liners Three tray types, chosen by part size, weight and cleanliness: ### 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. ### 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. ### 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. ### Examples ![Formed trays made by FUNYO](/assets/thin-gauge/trays.webp) Formed trays made by FUNYO ![New-energy large tray, 2.5 m × 1.1 m](/assets/ppt/large-tray.webp) New-energy large tray, 2.5 m × 1.1 m ![Formed tray for new-energy batteries](/assets/ppt/battery-tray.webp) Formed tray for new-energy batteries ![Formed tray for automotive parts](/assets/ppt/auto-parts-tray.webp) Formed tray for automotive parts ![Formed tray for precision parts](/assets/ppt/precision-parts-tray.webp) Formed tray for precision parts ![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. ## Where thermoformed trays and liners are used Explore related industries through equipment applications and component requirements. ### [Packaging & material handling](/en/industries/packaging-material-handling) Work-in-process, line-side supply and automated pick-and-place trays. ### [Electronics & advanced equipment](/en/industries/electronics-advanced-equipment) Precision component trays and anti-static handling trays. ### [EV, battery & energy systems](/en/industries/ev-battery-energy) Battery trays, insulating covers and formed brackets. ### [Automotive & transportation](/en/industries/automotive-transportation) Handling trays for automotive parts. ### [Medical & diagnostic equipment](/en/industries/medical-diagnostic-equipment) Handling liners for medical-equipment parts. ### [Agriculture & construction equipment](/en/industries/agriculture-construction-equipment) Seedling trays and growing boxes. ## Heavy-gauge thermoforming vs injection molding vs sheet metal How three common options compare: | | 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. ## Design options for thermoformed trays and liners Loaded stacking, empty nesting and fit in the tote are designed and tested separately. ### Loaded stacking Load between layers We define how load passes to the next layer, check clearances and run stack tests to the agreed height. ### Empty nesting Saves return space Draft and stops let empty trays nest; we test that they separate cleanly and don't jam. ### In the tote Totes · racks Checked against your tote or rack for inside dimensions, loading direction and room to lift parts out. We have an anti-nesting tester and drop-test equipment, so sample trays can be tested first. ## Sheet materials for thermoformed trays and liners “Black” or “thicker” doesn't define a tray. List load, contact surfaces, cleaning and ESD needs first, then pick the sheet. | 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. ### Small precision parts or clean trays? Thin-gauge thermoforming: formed in our cleanroom, up to 120 mm deep. [Thin-gauge precision trays](/en/capabilities/thin-gauge-thermoforming) ### Tray-specific equipment ![Tray washing line using DI water](/assets/thin-gauge/wash-line.webp) DI-water tray washing line developed in-house ![Anti-nesting tester](/assets/thin-gauge/anti-stack-tester.webp) Anti-nesting tester: checks empty trays don't jam ![Laser particle counter in use](/assets/thin-gauge/particle-counter.webp) Laser particle counter: checks cleanliness after washing ## Related product families - [Thermoformed Housings & Enclosures](/en/products/housings) - [Thermoformed Machine Covers & Shrouds](/en/products/covers-shrouds) - [Thermoformed Panels & Fascias](/en/products/panels-fascias) - [Thermoformed POP Displays and Light Box Faces](/en/products/displays-signage) - [Quality assurance](/en/quality/quality-assurance) - [Tooling & process engineering](/en/quality/tooling-process-engineering) - [Technical cleanliness](/en/quality/technical-cleanliness) ## 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) ## Heavy-gauge thermoformed trays and liners: FAQ 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. **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. - Part and use: e.g. motor housings between processes - Part size and weight: L × W × H (mm), unit weight - 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 #### 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. ## 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 Download your project brief, ready to share. Nothing is sent automatically. Last updated: 2026-10-22 ## Manufacturing guides - [Heavy-Gauge Thermoforming vs Injection Molding](/en/guides/heavy-gauge-thermoforming-vs-injection-molding) - [Thin-Gauge vs Heavy-Gauge Thermoforming for Parts](/en/guides/thin-gauge-vs-heavy-gauge-thermoforming) - [Thermoforming Materials Guide: ABS, PC, PVC & PP](/en/guides/thermoforming-materials-guide) - [Cleanroom Thermoformed Trays: Cleanliness Specs](/en/guides/cleanroom-tray-cleanliness-specification) - [Thermoformed Automation Trays: Tolerances and ESD](/en/guides/automation-tray-tolerance-stacking-esd)