Custom Plastic Boxes: Corrugated & Thermoformed

Ortho Development Corrugated Plastic Fabrication

Built to Your Size, Material, and Trip Count.

Off-the-shelf plastic boxes never fit. They are always a little too big, a little too small, or made from the wrong material for what’s inside them. The cost of forcing a part into the wrong box adds up in damaged parts, wasted void fill, and shelves full of containers nobody uses.

Kiva Container has built custom plastic boxes from corrugated plastic and thermoformed sheet since 1986. Two processes, one facility, owner-involved on every project. Whether you need a returnable plastic tote sized to your shelving system or a thermoformed clamshell built to one specific component, we build it from the right material in the right format.

Custom plastic boxes for shipping, storage, and assembly. Corrugated plastic, thermoformed, ESD-safe, Class A laminated, returnable, single-trip. Built in Anaheim, CA.

Two Processes, One Decision

Most buyers searching for custom plastic boxes don’t know whether they need corrugated plastic or thermoformed plastic. The right answer depends on the part, the trip count, and the budget. Here’s how to think about it.

Corrugated Plastic Boxes

Lightweight, durable, reusable, made from extruded fluted polypropylene sheet (also called coroplast, twinwall, or polypropylene corrugated). Available in 2mm, 3mm, 4mm, 5mm, 6mm, 8mm, and 10mm gauges depending on payload and trip count requirements. Die-cut on our flatbed press or CNC-routed on our 120 by 75 inch table.

Best for: returnable shipping totes, storage bins, large-format containers, kitting trays, dividers, dunnage, and any application where lightweight structure matters more than precise component fit.

Thermoformed Plastic Boxes

Vacuum-formed from solid plastic sheet against a custom aluminum tool, then trimmed to spec. Available in light gauge (0.015 to 0.060 inch) for clamshells and trays, or heavy gauge (0.090 to 0.500 inch) for industrial cases and containers. Tight tolerances against part geometry. Materials include ABS, polycarbonate, HDPE, PVC, PETG, conductive polymers, and ESD-safe substrates.

Best for: component-specific trays, clamshells, blister packs, custom-fit cases, ESD packaging for electronics, and any application where the box has to match the part it’s protecting.

Integrated Plastic Box Systems

Many of our customers need both. A thermoformed insert holds the component in position. A corrugated plastic outer box handles shipping and stacking. We design and build both in-house and assemble them as a single packaging solution. One supplier, one quote, one part number.

How to Choose

Process	Best For	Typical Lead Time
Corrugated Plastic	Returnable totes, storage bins, large boxes, dunnage	2 to 3 weeks after artwork approval
Light Gauge Thermoforming	Clamshells, trays, blisters, component carriers	3 to 5 weeks (includes tool build)
Heavy Gauge Thermoforming	Industrial cases, instrument housings, structural boxes	4 to 6 weeks (includes tool build)
Integrated System	Thermoformed insert + corrugated outer	Combination of the above

All boxes are designed, tooled, and built at our Anaheim, CA facility. No outsourcing. No middlemen.

Who Uses Custom Plastic Boxes

Aerospace and defense. AS9100D-certified custom boxes for avionics components, classified electronics, and assembly-line kitting.
Medical devices. Custom plastic boxes for sensor-integrated devices, surgical instruments, and diagnostic equipment.
Returnable plastic shipping boxes for tier-1 and tier-2 supplier programs, including ESD-safe versions for sensor modules.
Electronics and ESD. Conductive and static-dissipative plastic boxes for PCBs, ICs, photodiodes, and sensitive assemblies.
Material handling and AS/RS. Plastic boxes sized for automated storage and retrieval systems, vertical lift modules, and goods-to-person pick stations.
Industrial and supply chain. Reusable shipping boxes that pay for themselves over a year of trips.

Why Kiva Container

Both corrugated plastic and thermoforming under one roof. Most plastic box vendors do one or the other. We do both and integrate them.
In-house design and tooling. Aluminum CNC-machined thermoforming tools and steel rule dies, all built on our equipment.
AS9100D and ISO 9001:2015 certified for traceability and quality system compliance.
Full ESD material stock for static-sensitive applications.
Class A laminated surfaces for cosmetically sensitive parts.
Large-format CNC capability (120 by 75 inch) for oversized boxes.
No minimum order quantity. Prototype runs, short runs, and full production all welcome.
Woman-owned California small business. Founded 1986. Anaheim, CA.

Ready to Get Started?

Tell us about the part, the trip count, and any handling or environmental requirements. We will recommend the right process, material, and box design.

Request a Quote | Contact Us | 714-630-3850

Frequently Asked Questions

What's the difference between corrugated plastic boxes and thermoformed plastic boxes?

Corrugated plastic boxes are fabricated from extruded fluted polypropylene sheet (similar in structure to corrugated cardboard but plastic). They are lightweight, reusable, and best for shipping totes, storage bins, and large containers. Thermoformed plastic boxes are vacuum-formed from solid plastic sheet against a custom tool. They have tighter tolerances and conform to part geometry. Used for component trays, clamshells, and custom-fit cases. We make both in-house.

Can you make custom plastic boxes to any size?

Yes, within our equipment limits. Corrugated plastic boxes can be cut up to 78 by 150 inches on our flatbed die-cutter. CNC-routed boxes up to 75 by 120 inches. Thermoformed boxes up to 46 by 54 inches per part. Larger boxes can be designed as multi-piece assemblies with engineered joints.

What materials are available for custom plastic boxes?

Corrugated plastic in 2mm to 10mm gauges in a wide range of colors. Thermoforming substrates include ABS, polycarbonate, HDPE, HMWPE, KYDEX, PVC, PETG, PET, polyethylene, polycarbonate, conductive polymers, static-dissipative PVC, RPET, and specialty ESD-safe acrylics. We stock the most common materials so projects don’t wait on material lead times.

Do you make custom plastic shipping boxes?

Yes. Custom plastic shipping boxes are one of our core products. Available as single-trip or returnable, with or without dunnage, sized to your specific shipping requirements. Most customers choose returnable corrugated plastic for any part that ships at least quarterly because the cost-per-trip math beats disposable cardboard quickly.

Can you make ESD-safe plastic boxes?

Yes. Conductive plastic corrugated in 3mm and 4mm gauges for ESD-safe shipping and storage boxes. Static-dissipative thermoformed boxes available for component-specific applications. Both compliant with ANSI/ESD S541 packaging requirements.

What's the minimum order quantity for custom plastic boxes?

We do not impose minimum order quantities. We run prototype quantities, short runs of 50 to 500 pieces, and full production runs into the tens of thousands on the same equipment. The economics shift around 500 pieces for thermoformed boxes because the tooling cost amortizes faster, but small runs are absolutely welcome.

How long does it take to get custom plastic boxes made?

Lead time depends on the process. Corrugated plastic boxes typically take 2 to 3 weeks after artwork approval. Thermoformed boxes that require new tooling take 3 to 6 weeks including tool build. Prototype runs can be faster because we build tools in-house.

Can you print on custom plastic boxes?

Yes. Digital flatbed printing using our Canon 1260GT for short runs, low-quantity custom artwork, or full-color graphics. Screen printing on our automatic silk screen with UV dryer for high-volume runs. Print directly on corrugated plastic, thermoformed surfaces, hardboard, or laminated finishes.

Can you make custom plastic boxes with dividers?

Yes. Integrated divider systems for any custom box format. Dividers can be the same material as the box or different (for example, conductive corrugated outer with thermoformed conductive dividers). Designed to fit your container, your parts, and your assembly or shipping process.

Do you make custom plastic boxes for medical or aerospace use?

Yes. AS9100D and ISO 9001:2015 certified. Material traceability, audit documentation, and supplier qualification documents available. Common medical and aerospace applications include component trays, ESD-safe shipping boxes, Class A-finished cases, and cleanroom-compatible packaging.

Can I get a prototype custom plastic box before committing to a production run?

Yes. Prototypes are common. For corrugated boxes, we can cut samples on the flatbed die-cutter or CNC router without committing to a full die. For thermoformed boxes, we can produce prototypes on existing tooling, modify an existing tool, or build a prototype tool faster than vendors who outsource tool fab.

Are your custom plastic boxes made in the USA?

Yes. All design, tooling, and production happens at our single Anaheim, CA facility. No overseas freight. No tariffs. No supplier-side production stoppages.