Custom Returnable Packaging Partitions
You make a great part.
We help it arrive that way.
Bring us the part, a partial design, or a finished print. Duralok designs, refines, proves, and manufactures durable solid-HDPE partitions that keep components separated and protected through repeated handling and shipment.
The Middle Ground Between Corrugated Plastic and Injection Molding.
Corrugated plastic offers a lower initial cost, but its flutes can collapse under heavy loads and retain water, cutting fluids, and debris. Injection molding provides durability and repeatability, but the tooling investment makes sense only when production volumes are high enough to justify it.
Duralok fills the space between them: custom solid-HDPE partition systems that provide strength, design flexibility, washability, and repeatable production without injection-mold tooling.
Light duty
Corrugated Plastic
- Lower initial cost
- Flutes can collapse under heavy loads
- Can retain water, cutting fluids, and debris
- Best for light-duty applications
Duralok Solid-HDPE Partitions
- Solid-wall construction for heavy parts
- Fabricated using a Duralok-developed proprietary process—without injection-mold tooling
- No draft-angle or practical cell-depth constraints
- Best for flexible production runs where protection matters
High volume
Injection Molding
- Strong and highly repeatable
- Requires a significant tooling investment
- Best when production volume justifies the mold
- Design changes become more difficult after tooling is complete
Specialized Fabrication Process
Duralok has developed a specialized process for cutting and fabricating solid-HDPE partitions. It helps us turn challenging designs into repeatable production parts without injection-mold tooling.
- Solid-wall HDPE
- No injection-mold tooling
- No flutes to collapse
- Recycled material
- Recyclable material
- Flexible production runs
Start Wherever You Are.
Bring us the part, a partial design, or a finished print. Duralok can help complete, refine, and manufacture the right returnable packaging solution.
Start With the Part
Send us the part or provide its dimensions, weight, handling requirements, and return route. We can develop a custom partition concept around the application.
Bring a Partial Design
Bring us the sketch, drawing, or concept already in progress. We help complete the design and resolve the details needed for manufacturing and first-article approval.
Submit a Finished Print
Send the finished design or RFQ package. Before quoting or production, we review it for manufacturability and identify opportunities to simplify fabrication, contain cost, or improve the finished result.
Working with us is simple.
Share Your Starting Point
Send the physical part, photographs, dimensions, partial design, completed print, or RFQ package—whatever you currently have.
Design, Refine, or Review
We create the partition design, complete an existing concept, or review a finished design for manufacturability and cost-containment opportunities.
Build and Approve the First Article
We manufacture a first article so the fit, protection, handling, and construction can be evaluated before full production.
Produce the Approved Design
After approval, our specialized fabrication process turns the proven design into a consistent production order.
Is your project a fit?
We would rather tell you early than quote work we are not the right shop for.
Strong fit
- The customer already uses returnable packaging
- Heavy metal or machined parts need separation and protection
- The project may begin with a part, a concept, a partial design, or a completed print
- The application needs a durable custom solution without injection-mold tooling
- Corrugated plastic is failing under load or retaining moisture
Poor fit
- Extremely high volumes that justify injection molding
- Projects requiring unsupported ESD certification
Built to Come Back Clean and Dry.
- Solid-wall HDPE
- Solid material through the full thickness for strength and repeated use.
- No flutes
- No internal channels to collapse or trap water, coolant, and debris.
- Recycled or virgin material
- Sheet stock available in recycled or virgin HDPE, per your requirements.
A Manufacturing Partner That Protects Your Customer Relationship.
Duralok is built to work with packaging distributors. You own the customer relationship; we provide the design and manufacturing expertise that helps you deliver difficult projects successfully.
How We Work With DistributorsRecent work.
Need a Custom HDPE Part Beyond Returnable Packaging?
Duralok's proprietary fabrication process can support select custom solid-HDPE applications beyond partition systems. Bring us the part, drawing, or application, and we'll help determine whether it's a fit.
Explore Custom HDPE Fabrication