Prent Corporation

Chris Bladl

Packaging Automation Specialist

In the past, injection molding  was considered the most reliable  way to make automation trays  for the electronics, medical, and  automotive industries because it  could produce the tightest tolerances.  However, today’s advances in highprecision  thermoforming technology  provide tolerances as low as 0.010 in.  and positioning tolerances within .020  in., satisfying custom requirements  for nearly any vision or pick-to-place  automation line.

Thermoformed automation trays provide  several benefits over injection molding. 

Lower cost per tray 

A thermoformed automation tray costs about  half that of injection molded trays. This is  because cycle times are shorter, the raw  material costs are lower, and it requires less  plastic to produce. The up-front cost is also  reduced: thermoform tooling costs are often  75% lower than injection molding tooling. 

Faster setup 

Thermoform tooling is faster to produce,  so it can be delivered in an average of four  weeks, versus the 10 to 12 weeks it may take  to have new injection mold tooling. That  means shorter lead times and speed to market  for manufacturers using thermoformed trays  . 

Better product protection 

Injection molded trays are rigid, so during  shipping, products are subject to vibration  and possible damage if a package is dropped.  This is especially dangerous for fragile, hightech  components such as computer chips and  medical devices.

“The best way for component manufacturers to determine if thermoformed automation trays are the best option for their needs is to contact a thermoformer early in the development phase”

 In those instances, additional packing  materials are needed to protect the product.  In contrast, products in thermoformed  automation trays travel more safely because  the material flexes slightly to absorb shock  and vibration. 

Lighter weight 

The weight of thermoform plastic in an  automation tray is lighter than injection  molded plastic, so shipping costs are  lower. With rising fuel prices, lower  freight expenses can add up to big savings,  especially for international shipping. 

More sustainable 

Compared to an injection molded tray,  thermoformed trays use less energy to make  because they require less heat, pressure,  drying, and cooling. In freight transport, the  lighter-weight thermoformed trays produce  lower CO2 emissions.

Also, thermoforming uses polyethylene  (PET), which is the easiest plastic to recycle  after use. It’s the same plastic used in many  common consumer packages that are picked  up by curbside recycling programs. Injection  molding commonly uses Acrylonitrile  butadiene styrene (ABS), which is more  difficult to recycle and often not accepted in  community recycling programs, so it ends  up in landfills. 

Because PET is so easy to recycle, some  thermoformers use recycled materials in their  trays, reducing the waste in the production  process. In fact, a large percentage of  that recycled PET can be post-consumer  material, further reducing plastic waste. 

Another option

Manufacturers of components for the  electronics, medical, and automotive  industries no longer need to settle for  injection molding as the only solution for  automation trays. Thermoforming provides  benefits in cost, speed, and sustainability. 

The best way for component  manufacturers to determine if thermoformed  automation trays are the best option for their  needs is to contact a thermoformer early  in the development phase. In some cases,  thermoform engineers can recommend  tray designs that optimize the automation  process.