Development of a Thermoformed Cushion End Cap for the Electronics Industry

Development of a Thermoformed Cushion End CapA manufacturer of electronics needed a low cost solution for the packaging of one of their product lines. As the photo here shows, they needed a thermoformed end cap that would suspend their product inside of the package. It would have to be durable enough to protect the item from damage during shipping and handling, but inexpensive enough to not drive up the cost of the product.

The product that we engineered features patented shock absorbing bumpers that are specially designed to prevent damage from rough handling. The finished product not only met all of the customer’s requirements for packaging, but also reduced their cost because of our innovative use of materials.

At Plastiform, we integrate value into every product that we engineer and manufacture. This packaging solution was composed of a black medium density polyethylene (MDPE) that is formulated from postconsumer recycled materials. It was manufactured on an in-line thermoformer, with a smooth finish and dimensions of 8″ by 5″, to tolerances of ±.010″. A prototype was produced and approved before the production run of 8,000 units. Quality was maintained through fit and destructive testing to verify dimensions and wall thickness. This product highlights our ability to combine innovative features into an existing product.

Use the table below to learn more about our custom electronics packaging or contact us directly.

Request Information

(Click on thumbnail to enlarge)

Highlights of this Precision Thermoformed Project

Product Name

Cushion End Cap

Project Scope

Package a new product in required box size and protect from impact damage

Product Description

End caps that suspend part inside box.

Thermoforming Capabilities Applied/Processes

Product Design/Development

Equipment Used to Manufacture Part

Single Station Thermoformer

Overall Part Dimensions

Product Length: 8″
Product Width: 5″

Tightest Tolerances

± 0.010″

Material Used

Medium Density Polyethylene (MDPE)
Postconsumer Recycled
Material Thickness: 0.060″

Material Finish

Black, Smooth

Special Features

Patented Shock Absorbing Bumpers to Prevent Damage from Rough Handling


Combining Proven Features into an Existing Box

In process testing/inspection performed

Fit Testing of Product
Measuring Wall Thickness in Critical Areas

Industry for Use




Delivery/Turnaround Time

5 Weeks

Standards Met

Customer Design Requirements

Delivery Location

Dallas, Texas