Prent Corporation

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 high-precision 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, high-tech components such as computer chips and medical devices. 

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.