An aerospace and defense manufacturer needed to protect extremely sensitive, thin, coated optics — each valued at $300–$400 and sensitive to any contact on the clear aperture — throughout the work-in-process, handling, and storage in the cleanroom. Each tray/cover set holds 100 parts, so a single tolerance failure could put thousands of dollars of product…

Our customer required a static dissipative plastic tray to transport parts that are not ESD sensitive but will later be combined with ESD-sensitive components at a secondary facility. The tray helps maintain an ESD-safe environment throughout the supply chain while protecting parts during handling and transport. The tray was designed to support efficient production and…

An OEM required a safer way to transport and service a large painted assembly weighing over 50 pounds. Our solution addressed both safety and product protection, incorporating lift straps for secure two-person handling, surface protection to prevent scratching, and full ESD protection for use inside and outside the ESD-protected area (EPA). A “top hat” cover…

An OEM partnered with a contract manufacturer to produce high-value printed circuit board assemblies and needed a reliable way to transport them safely from the contract manufacturer to their facility. The solution: a custom-designed mailer with an engineered thermoformed plastic tray and lid that delivers both physical protection and ESD safety—while seamlessly integrating into the…

Automotive electronics subcontractors operate under strict standards for quality, reliability, and process efficiency. One of our long-standing partners requested a “work-in-progress” solution to streamline their production environment. Their goals were clear: remove non-essential components from the work area, improve line efficiency, and reduce the risk of physical and ESD damage. We delivered a custom-engineered system…

A custom thermoformed insert was designed to fit within an existing tote used in the manufacturer’s process, replacing standard dividers that failed to properly secure the product and had led to damage of high-value components. The tailored tray securely held each unit in place, eliminated prior handling challenges and significantly enhanced protection. The thermoformed design…

An automotive electronics subcontractor required a universal packaging solution to transport four different PCBA designs between Mexico and the U.S. This custom-engineered Durastat ribbed adjustable tote provided the answer—its CFP construction, card guide slots, and adjustable dividers securely accommodated all board sizes while preventing contact with sensitive components. By implementing a single, adaptable tote design,…

We developed a custom process tray for a commercial electronics manufacturer, designed to move products safely and efficiently throughout the facility. To prevent finger entrapment when placed on low carts, the tray featured extended handles formed by bending a custom wire rim. The structure combined sonic-welded conductive fluted plastic (CFP) with the wire frame, providing…

This solution employed conductive thermoformed trays designed to fit seamlessly with customer-owned injection molded totes, typically sized at either 9″ × 15″ or 15″ × 20″. Each tray featured multiple cavities to securely hold circuit boards, enabling efficient stacking and transport both within the facility and to external locations. The new custom handling method eliminated…