Mold nests or cavities can be diverse: rectangular, round, custom-shaped, tracks, ribs, or domes. So how is it decided which mold nest is the right one? More on this in the article.
Lisa-Marie Bittner
Updated on September 29, 2026
→ Upload your 3D component in our 3D Tray Generator: The form nest is automatically adapted to your data.
Form nests are cavities that accommodate the component. Cavity is derived from the Latin "cavum" and means hollow. Simply put, form nests are recesses in the workpiece carrier that ensure safe transport of the component and simplified loading and unloading of the tray.
The shape of the cavity that accommodates the component is in many cases the critical point in functionality. Whether for inlays, blister packs, trays or workpiece carriers – how well the cavity is adapted to the product determines efficiency and safety during handling, transport and storage.
Form nests: Different nest contours
In intralogistics and extralogistics, cost optimization is paramount. Important factors include:
When investing in the development of a new transport tray, universal tray design is often required. Different component variants or component families can be transported in a universal tray.
This saves tool costs during cavity production that would otherwise be incurred for each tray variant. This means the form nests must be adapted to different components.
A cavity is always aligned to the original component. This is done using the CAD data of the components, a component sample, or an existing tray.
Creating data via the CAD data of the component is best for both customer and formary: On one hand, we can optimally measure CAD data from all sides. No time-consuming iterations in data adjustment are needed.
Second, we can adjust details virtually in advance, such as the distance between component and nest inner wall. Before creating the data, we will of course have you sign a confidentiality agreement / non-disclosure agreement.
Tip: In our 3D Tray Generator, the form nests are automatically adapted to your component data.
The second option is to create the form nest data based on a component sample. Depending on the structure of the component, we can either measure manually or use an optical measuring device.
As a third option, we can also reverse-engineer the data based on an old tray sample, i.e. we measure the part with a Faro Arm. An existing disadvantage is that any imperfections on the tray surface are also transferred, which then exist in the data model.
It is always important that all other requirements such as tolerance of centering points (for automation trays), grid dimensions and desired dimensions on the nest bottom are communicated. The more details coordinated in advance, the more error-free the data design will be.
The answer is yes. After the nest design has been created in the CAD program, functionality can be tested via various sample options (see also Prototypes or our blog post Rapid Prototyping)
The choice therefore depends on
The form nests can be adjusted depending on the tool design:
| Tool Design | Adjustment of form nests in this direction possible | Adjustment of form nests in this direction not possible |
|---|---|---|
| Negative tool | Deepening the form nests
| Raising the form nests |
| Positive tool | Raising the nests
| Deepening the form nests |
The correct design of form nests determines packing density, component protection and efficiency in transport and production. Those who consider early on requirements such as minimum distances, draft angles and automation parameters save time and costs and increase process reliability.
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Form nests or cavities are recessed compartments in plastic trays or inlays in which components are transported or stored.
