Aerospace

Custom Thermoformed Trays


Eliminated FOD, ESD & Excess Packaging with Streamlined Stackable Tray Design

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 the need for bags, foam inserts, multiple totes, and pizza-style boxes—streamlining logistics while reducing the risk of foreign object debris (FOD). For added protection, Kleanstat Flex™ pads were incorporated into the bottom of each tray, providing cushioning and ESD-safe contact surfaces.

To ensure audit readiness and compliance, each tray included an embossed ESD symbol, clearly indicating its electrostatic discharge safety rating.

Requirements Met

  • ESD-safe solution with Kleanstat Flex™ pads for cushioning
  • Multi-cavity design secured boards during transport
  • Conductive trays fit existing 9” × 15” or 15” × 20” totes
  • Eliminated bags, foam, and excess packaging