Engineering and Development of a custom PETG Tray & Lid for the Medical Industry

In this project, a manufacturer of medical devices needed us to engineer a packaging system for PETG trays and covers that would be used in the operating room during surgeries. The package required an ergonomic design to allow for easy opening during use. At Plastiform we are a full service provider of engineering, design, and complete thermoforming services, specializing in turn-key solutions such as the project highlighted here.

From the customers design requirements, we developed a concept and prototype which utilizes an inner tray that nests inside an outer tray, with a lid that covers the contents. The lid included vertical lugs which held the product in the tray, with primary and secondary perimeter surfaces, and tabs with finger clearance corners to allow for easy removal of the Tyvek seal. The finished product measured 10.25″ in length, 5.00″ in width, with material thickness of .035″.

The prototype and production run of 500 pieces was completed on a single station thermo-former that utilizes a portable laminar flow hood to reduce packaging contamination. This capability also allowed us to achieve tolerances of ±.002″.

Fully inspected and tested, this project, from concept to delivery, was completed in just 6 weeks. For more information on this project or our processes used to manufacture custom handling trays, see the table below or contact us directly.

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Highlights of this Engineering & Thermoforming Project

Product Name

Inner Tray/Outer Tray and Lid

Project Scope

Package newly designed component in ergonomic package for surgical use.

Product Description

Inner tray nests inside outer tray and lid covers component. Tabs for finger clearance and truncated corners for ease of Tyvek seal removal.

Capabilities Applied/Processes

Design Concept


Utilize laminar flow hood to reduce packaging contamination.

Equipment Used to Manufacture Part

Single Station Thermo-Former and Portable Laminar Flow Hood.

Overall Part Dimensions

Product Length: 10.25″
Product Width: 5.00″

Tightest Tolerances

± 0.002″

Material Used

PETG – Blue Tint FDA
Material Thickness: 0.035″

Material Finish

Blue Tint

Special Features

Lid features vertical lugs to hold product in tray. Primary and secondary perimeter surfaces for Tyvek Seal


Three nesting components cleanliness requirement by customer.

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

Customer Design Requirements

Delivery Location

Dallas, Texas