Component Safety for Your Small Parts: How Thermoformed Plastic Inserts Ensure Secure Transport

Safety of small components – Key points at a glance

• Plastic thermoformed inserts hold delicate components securely in place and protect them from knocks, scratches and moisture.
• They provide mechanical, chemical and, where required, electrostatic protection for components during transport and storage.
• The precise design facilitates safe handling and reduces damage during transport across a range of industries.
• Thanks to their reusability and durability, they offer a cost-effective solution for structural safety.

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What Is Component Safety?

Definition: Component safety includes all measures designed to protect sensitive or valuable components from damage. This involves specialized packaging solutions and transport aids that ensure secure handling. Protection can include the following aspects:

1. Mechanical Protection – Prevents scratches, impacts, dents, or other damage from external forces.
2. Chemical Protection – Shields components from corrosion, moisture, or harmful chemicals.
3. ESD Protection – Prevents damage from electrostatic discharge (ESD), which is especially crucial in the electronics industry.

How Thermoformed Plastic Inserts Protect Your Components

Thermoformed inserts, also known as inlays, are produced using the plastic thermoforming process. Through sheet or roll production, plastic films are heated and shaped into a mold. The result includes not only inserts but also plastic trays, covers, and containers.

These inserts securely hold products or bulk materials in a custom-fit blister within a container or box. Their precise shape prevents movement, ensuring that sensitive components remain in place. This is especially crucial for delicate parts or products that require a specific orientation during assembly. By securing components, thermoformed inserts prevent transport damage and ensure component safety.

Design features of standard thermoformed inserts

When designing thermoformed inserts, the following points are taken into account:

• Custom-shaped sockets: Round, square or ribbed, depending on the component geometry.
• Clamping devices: Hold sensitive products securely in place.
• Minimum punch margin: Ensures a flush finish with the container and prevents slipping.

These features ensure that components are stored securely and stably in any transport situation.

Component Safety for ESD-Sensitive Parts

In the electronics industry, protecting delicate components from electrostatic discharge (ESD) is crucial. This electrical discharge can irreparably damage electronic parts, leading to production failures or quality defects.

To prevent this, ESD-Inserts and ESD-Trays are specially designed to securely store and transport electronic components, ensuring safe handling throughout the logistics chain.

Industries That Rely on Thermoformed Inserts for Component Safety

Thermoformed plastic inserts serve as protective transport solutions across various industries. Here are some examples:

Why Are Thermoformed Plastic Inserts Ideal for Component Safety?

Thermoformed plastic inserts are frequently used as durable inserts in small load carriers (SLCs) and Euro-standard containers for small parts that are regularly subjected to heavy use. In cases of intensive mechanical use, such as with heavy tools, the material of the SLC inserts must be particularly robust. Plastic is therefore the preferred material for thermoformed inserts due to its versatility and robustness. 

Plastic properties

• Lightweight and durable: Plastic reduces the overall weight of thermoformed packaging and can withstand even heavy use.
• Flexible and malleable: Plastics can be easily heated and moulded into almost any shape, allowing for a wide variety of designs.
• Shock-absorbing: Thermoplastics offer good shock absorption, making them ideal for shock-absorbing applications.
• Chemical and corrosion resistant: As a rule, most plastics do not react with water, acids or alkalis, making them ideal for use in damp environments and in chemical processes.

Commonly used plastics

• PS (polystyrene)
• ABS (acrylonitrile-butadiene-styrene copolymer)
• and PP (polypropylene).

When designing the insert, it is important to consider the requirements that the plastic material must meet in order to ensure that the components are adequately protected during transport.

Component safety for your components – with formary Standard thermoformed inserts

Effective component protection is essential for ensuring that products reach their destination safely and undamaged. Do you have any questions or would you like a personalised consultation? Please feel free to contact us; we will help you find the ideal transport protection solution.