In this project, a manufacturer of medical devices needed us to engineer a packaging system for custom 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.


I found Plastiform when I was in a bind with another vendor. I had been strung along by my original vendor and needed a new vendor as soon as possible. We received our first order on time and the quality of the parts were exactly the same as the samples we had received. I am so thrilled that we found and worked with Plastiform on this project.

Taylor Clark

R.N.C. Industries, Inc

We sincerely appreciate your efficient and gracious customer service and the level of detail and accountability you have demonstrated on the design, prototype, production, and delivery of the falafel trays.  We are delighted with the way you conduct business as a whole.

Tova Chansky

Tovavi Falafel

Where do we begin, Plastiform has been above and beyond anything we could have asked for. Donna and the team has been AWESOME during this whole process. Would highly recommend them !!!

Brad & Cheryl Sims

Alumi-Tee, LLC

Working with the Plastiform team has been a pleasure. Given the amount of time and work spent on our startup company, it has been refreshing to see them operate with a high level of communication.  We were impressed by how our custom product turned out and how quickly we received samples to approve.  We will keep this in mind as we make decisions on any future packaging needs.  Thank you Plastiform!



To agility save time and money, my team and I agreed to buy an off the shelf plastic mold form.   We then would create a custom insert to secure our new wrist watch products. I didn’t realize how dumb this was until Operations Manager, Donna Lee talked me off the ledge of “Packing Gone Wrong”. With her patience, insight and professional guidance we were back on track after our first phone call.

From thumbnail sketch to finished custom packing we couldn’t be happier! Plastiform not only saved us time and money! Donna created a production template for our brand extensions

Slew Wilkins

(Creative Director)TheSwankyGuy, LLC


ISO - Medical Tray with Lid
SPE - Medical Tray with Lid
Institue of Packaging Professionals - Medical Tray with Lid