Custom ESD HIPS/PET Thermoformed Trays, PP Corrugated Plastic Packaging and PP Honeycomb Packaging

In the production, handling and distribution of electronic components, PCBs and PCBAs, semiconductor modules, display panels and automotive electronics, packaging must do more than contain and protect the product. It must also help reduce electrostatic charge accumulation and electrostatic discharge risks for sensitive devices. Because products vary in size, weight, positioning accuracy, reuse frequency and stacking method, they also require different ESD packaging structures.

Yufa addresses three core requirements—precision positioning, lightweight reusable logistics and high-strength load support—with ESD HIPS/PET thermoformed trays, ESD PP corrugated plastic boxes and ESD PP honeycomb packaging. Each solution can be used independently or combined with boxes, trays, interlocking dividers, lids and inserts to create an integrated packaging system for the product and logistics process.

1. Three Materials for Three Different Packaging Tasks

When selecting ESD packaging, sheet thickness and unit price should not be the only considerations. A better approach is to first determine whether the product requires precision cavities, flexible partitioning, or large-format high-strength load support, and then select the material and structure.

Note: The thicknesses and sheet weights shown are Yufa’s standard configurations. Final dimensions, load capacity, color, resistance range and structure should be confirmed according to the product, operating environment and approved sample.

2. ESD HIPS/PET Thermoformed Trays: Precision Positioning with Permanent ESD Performance in Black or Custom Colors

ESD thermoformed trays use product-matched cavities to control orientation, spacing and quantity. This reduces part-to-part contact during handling, buffering and transportation. They are particularly suitable for smaller electronic parts that require accurate positioning and orderly presentation, and they can also support robotic handling, production lines and in-process transfer.

Yufa focuses on two materials in this product range: ESD HIPS and ESD PET. In addition to standard black, permanent ESD performance is available in custom colors. Across different colors and both materials, the surface resistivity range remains 1.0×10⁵ to 1.0×10⁹ Ω/sq. Color can therefore be used to distinguish product models, process status, production lines or circulation areas while maintaining the same ESD control range. Compared with temporary surface treatments, a permanent ESD formulation is better suited to applications requiring stable performance over repeated use.

How Should You Choose Between ESD HIPS and ESD PET?

• ESD HIPS: Suitable for trays requiring toughness, efficient thermoforming and multiple color options. The surface resistivity range is 1.0×10⁵ to 1.0×10⁹ Ω/sq.

• ESD PET: Suitable for applications requiring PET material characteristics, appearance and custom forming. The surface resistivity range is also 1.0×10⁵ to 1.0×10⁹ Ω/sq, with the same range available in black and custom colors.

• Structural limitation: Thermoforming height is limited. These materials are intended for trays and internal inserts rather than large box structures.

By customizing cavity quantity and depth, pick clearance, stacking direction, mistake-proofing features and edge design, a thermoformed tray can progress from simply “holding the product” to providing stable positioning, efficient handling and process compatibility.

Example of an ESD HIPS/PET thermoformed tray (structure, color and cavities can be customized)

3. ESD PP Corrugated Plastic Packaging: Lightweight, Flexible and Suitable for Boxes and Divider Systems

ESD PP corrugated plastic sheet consists of two outer skins connected by internal ribs, providing structural support while keeping the material lightweight. Yufa’s standard material is 5 mm thick with an approximate sheet weight of 950 g/m². It can be fabricated into returnable boxes, trays, interlocking dividers, partitions and inserts, making it a versatile option for electronics manufacturing and internal logistics.

The sheet can be cut, creased, folded, welded or assembled with connectors into different structures, including foldable boxes. When empty, the box can be folded to reduce space during delivery and return transport, helping lower associated logistics costs. For heavier loads, stacking or frequent handling, lids, divider sets, aluminum edge profiles or reinforcing bars can be added to balance low weight with structural stability.

Common Custom Configurations

• Box + interlocking dividers: Separates and positions multiple products in one box, reducing direct contact and mixed storage.

• Box + lid: Improves dust protection and transport protection; available with a separate lid or an attached lid.

• Foldable box + interlocking dividers: Reduces empty-box transportation costs.

• Aluminum reinforcement: Added to the rim, corners or primary load-bearing areas to improve stability and handling durability.

Current technical data for the corrugated plastic box specifies a permanent ESD surface resistance range of 10⁵ to 10⁹ Ω and a typical service temperature of −10°C to +70°C. These values are useful for selection; finished-product performance should still be verified against the sheet batch, box structure and actual test results.

Example of an ESD PP corrugated plastic foldable box with interlocking dividers

4. ESD PP Honeycomb Packaging: Designed for Large Boxes and Higher-Strength Returnable Use

As packaging dimensions, load weight or reuse frequency increase, standard corrugated plastic may not provide the required combination of flatness, compression resistance and durability. ESD PP honeycomb sheet uses a multi-layer structure with PP skins and a honeycomb core, making it a structural upgrade within the ESD PP packaging range.

Yufa’s standard honeycomb sheet is 4 mm thick with an approximate sheet weight of 1,200 g/m². Although its nominal thickness is lower than that of the standard 5 mm corrugated sheet, the two materials have different internal structures and material usage per unit area. Strength should therefore not be judged by thickness alone. The honeycomb core provides a stronger overall structure, making it particularly suitable for large ESD boxes, load-bearing trays, support baseboards and reusable structural dividers.

Why Is It Suitable for Large Packaging?

• Higher overall structural strength: Suitable for large box walls, base panels and tray bases.

• Greater durability: Designed for frequent circulation, repeated loading and unloading, and long-term returnable use.

• Complete accessory options: Can be combined with dividers, lids, inserts, labels and identification features.

• Suitable for heavier products: Applicable to PCBAs, modules, heavier boards and automotive electronic components.

Current honeycomb sheet data specifies a permanent ESD surface resistance range of 10⁴ to 10⁸ Ω and a typical service temperature of −10°C to +70°C. Final structures should be validated according to box dimensions, load weight, stacking layers, handling method and operating temperature.

Example of an ESD PP honeycomb tray

5. Combine the Three Materials into One Packaging System

Many projects do not require an “either-or” choice among the three materials. For example, a PP corrugated plastic or PP honeycomb outer box can be combined with thermoformed trays for precision positioning. A honeycomb sheet can provide the structural strength for the box and base, while corrugated plastic dividers provide flexible internal separation. The key is to assign each packaging function to the material best suited to perform it.

6. Six Items to Confirm Before Custom Design

To develop a solution that reflects the actual application, provide the following information before design begins:

• Product details: Overall dimensions, unit weight, scratch sensitivity and ESD sensitivity level.

• Loading method: Quantity per box, product orientation, mistake-proofing requirements, and whether individual cavities or divider separation is required.

• Logistics conditions: Internal circulation or export shipment, manual handling or automated conveying, and stacking requirements.

• Frequency of use: One-way shipment, occasional reuse or high-frequency returnable circulation.

• Accessories: Lid, handles, dividers, aluminum reinforcement, document pocket, barcode or QR code.

• Acceptance criteria: Target surface resistance range, dimensional tolerances, load testing and any customer-specific standards.

Conclusion

Yufa Polymer provides custom ESD packaging in ESD HIPS/PET thermoformed trays, PP corrugated plastic and PP honeycomb structures. Send us your product drawing, dimensions, quantity per pack and operating conditions for a tailored recommendation.

Contact Yufa Polymer | Email: qiaoyang@yufapolymer.com