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Custom Thermoforming of ABS Material for Shipping Trays

Custom Thermoforming of ABS Material for Shipping TraysCustom Thermoforming of ABS Material for Shipping Trays

An auto parts manufacturer contacted Lane requiring a custom thermoformed shipping tray constructed of ABS. The client had an existing product that they wanted to replace with a reusable item made from recycled plastic. It had to be environmentally friendly, and be able to stand up to hard use.

They provided us with specific dimensions for the piece, which was designed to protect the automobile components that they manufacture. The trays needed to capture the banding straps that would fasten the stacks of loaded parts trays, and include stacking and nesting features to save space when empty. The stackable design also required that the top and bottom sections fit without shifting.

We purchased recycled ABS, and thermoformed the top and bottom sections, as well as thermoforming their logo onto the product. A haircell texture was also applied to resist scuffing. We then precision CNC routed both sections, and submitted the first part to the customer for approval. During the production run we performed fit tests and inspections to ensure quality.

For more information on this particular project, or to find out how Lane Plastics can serve your needs, please contact us.

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Project Highlights of ABS Material for Shipping Trays

Product Description
  • Shipping tray to protect automobile components.
Capabilities Applied/Processes
  • The customer had an existing system but wanted a more reusable, environmentally friendly solution.
  • We purchased recycled ABS.
  • Thermoforming
    • The top and bottom were thermoformed
    • Customer's logo is thermoformed into product
  • CNC Routing
    • Routing of Top and Bottom Pieces
    • There is also a flat CNC routed insert packed inside the front and back
  • The top and bottom were engineered to fit snugly and not shift, with formed nesting features and grooves to capture banding straps.
  • Parts designed to stack when loaded and nest for compact return shipment when empty.
Equipment Used to Manufacture Part
  • CNC router and Thermoformer
Tightest Tolerances
  • ±.03"
Material Used
  • Black recycled ABS
Material Finish
  • Haircell texture to resist scuffing in use
In process testing/Inspection performed
  • Part of first approval sent to customer, print provided by Lane
  • Company was approved by customer and used to qualify parts.
Industry for Use
  • Shipping container
Delivery Location
  • Texas
Product Name
  • Component shipping system

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