Medical Pipette Trays

After a thorough evaluation of the medical pipettes, the Plastiform team concluded that utilizing thermoforming as the manufacturing method would maximize the cost benefit of the item. It also allowed us to design and engineer a new product with enhanced features that were not cost effective with the injection molded version. We included characteristics such as a lid that can be opened with one-hand, enhanced wall rigidity with the use of corrugation, and an inner tray and low retention perimeter snap. Composed of Polyethylene Terephthalate Glycol (PETG), it has dimensions of 8.32″ in length, 5.25″ in width, with a wall thickness of .030″.

The medical pipette tray was produced on a single station thermoformer, which allowed us to achieve tolerances of ±.002″. Various quality control measures were applied to verify function and design specifications, such as fit and destructive testing, and verification of material thickness. Upon approval of the prototype, we produced 100 of these products, with the entire project requiring a lead time of only 6 weeks.

Prior to the creation of thermoformed pipette trays, we were contracted by a manufacturer of medical devices to find a low cost solution to produce the pipette tray. At Plastiform Dallas, innovation and cost reduction of manufactured products is part of our culture.

The customer was having this pipette tray manufactured using injection molding. The complexity and detail of the design resulted in high costs for tooling and production using this method. The thermoformed design that the Plastiform team created for this unique product is just one example of how any custom, one-of-a-kind product packaging can be produced by Plastiform.

To learn more about this project, or our manufacturing process for handling trays, see the table below or contact us directly.

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Highlights of this Custom Designed & Thermoformed Project

Product Name

Pipette Tray

Project Scope

Replace more costly injection molded tray with a hinged box solution.

Product Description

4 x 5 box with lid that can be opened one-handed. Retains a board with components inside.

Design & Development of a Thermoforming Capabilities Applied/Processes

Product Design/Development

Equipment Used to Manufacture Part

Single Station Thermoformer

Overall Part Dimensions

Product Length: 8.32″
Product Width: 5.25″

Tightest Tolerances

± 0.002″

Material Used

Polyethylene Terephthalate Glycol (PETG)
Material Thickness: 0.030″

Material Finish


Special Features

One handed lid opening.
Corrugation on side for additional wall rigidity.


Inner tray snap feature and low retention perimeter snap on lid

In process testing/inspection performed

Fit Testing of Product
Destructive Testing
Cutting the Part and Measuring Material Thickness

Industry for Use




Delivery/Turnaround Time

6 Weeks

Standards Met


Delivery Location

Customer Design Requirements

Why did you choose this project to show case?

This product successfully highlights a conversion to thermoforming.