Custom Reusable Packaging Solutions

Your Partner in Packaging Design Engineering

DDC-Omni collaborates with packaging designers and engineers to develop custom reusable packaging solutions that protect your products throughout their entire supply chain lifecycle. With over 70 years of foam and rubber fabrication expertise, we transform your packaging concepts into precision-manufactured dunnage, protective inserts, and complete returnable packaging systems.

Collaborative Design Partnership

We understand that packaging designers need a manufacturing partner who can execute their vision with precision and consistency. Our team works closely with you to:

• Material Selection: Help specify the optimal foam, rubber, or EPDM material for your application's unique requirements
• Design Refinement: Provide manufacturability feedback to optimize your designs for production efficiency
• Prototyping: Quickly produce samples for testing and validation before full production
• Testing Support: Assist with compression testing, drop testing, and performance validation
• Production Scaling: Seamlessly transition from prototype to low-volume through high-volume production
• Cost Engineering: Identify opportunities to reduce total cost of ownership while maintaining performance

Custom Dunnage & Insert Applications

Our reusable packaging solutions protect products across diverse industries:

• Automotive: Engine components, transmission parts, body panels, and electronic assemblies
• Electronics: Circuit boards, displays, sensors, and sensitive instrumentation
• Aerospace: Precision machined components, avionics, and tooling
• Medical Devices: Surgical instruments, diagnostic equipment, and sterilized components
• Industrial Equipment: Hydraulic components, bearings, motors, and precision tooling
• Defense: Sensitive equipment, weapons systems, and tactical gear
• Telecommunications: Network equipment, fiber optic components, and testing devices

Material Capabilities

We fabricate custom packaging from a comprehensive range of materials to meet your exact specifications:

Foam Materials

• Polyethylene Foam: Excellent shock absorption, available in various densities (2 lb to 9 lb)
• Polyurethane Foam: Superior cushioning with excellent compression set resistance
• EVA Foam: Flexible, durable, and chemical-resistant for harsh environments
• Cross-Linked Polyethylene: Closed-cell structure for water resistance and longevity
• Convoluted Foam: Egg crate patterns for enhanced cushioning and air circulation
• Anti-Static Foam: ESD-safe materials for electronics protection (pink, black conductive)
• High-Density Foam: Load-bearing applications requiring structural support

Rubber & Elastomer Materials

• EPDM Rubber: Weather-resistant with excellent compression set properties
• Neoprene: Oil and chemical resistance for industrial environments
• Silicone: Extreme temperature range (-60°F to 450°F) applications
• Natural Rubber: High elasticity and tear resistance
• Nitrile (Buna-N): Outstanding oil and fuel resistance

Manufacturing Capabilities

Our advanced fabrication capabilities ensure your designs are executed to specification:

• Die Cutting: Steel rule dies for high-volume production with tight tolerances
• Punch Press: High-speed production for simple geometries
• Lamination: Multi-layer constructions combining different materials and densities
• Slitting & Sheeting: Custom widths, lengths, and thicknesses from bulk stock
• Assembly: Multi-component packaging systems with adhesives, fasteners, or mechanical attachments

Value-Added Services for Packaging Designers

• CAD Support: Work from your technical drawings
• Adhesive Application: Pressure-sensitive adhesive (PSA) lamination for easy installation
• Color Matching: Custom colors for brand identity or organizational systems
• Labeling & Marking: Part numbers, barcodes, or handling instructions
• JIT Delivery: Inventory management and scheduled releases to support lean operations
• Material Certifications: Full documentation including material specs, test reports, and compliance certificates

Quality Assurance & Compliance

Our quality management system ensures consistent execution of your packaging designs:

• ISO 9001:2015 certified manufacturing facility
• First article inspection (FAI) and approval process
• Dimensional verification using calibrated measurement equipment
• Material certifications and test reports from approved suppliers
• Lot traceability for full supply chain visibility
• Statistical process control (SPC) for high-volume production
• PPAP (Production Part Approval Process) documentation available
• Compliance with REACH, RoHS, and other regulatory requirements

Prototype to Production

Our flexible manufacturing approach supports every stage of your packaging development:

• Rapid Prototyping: CNC routing for quick design iteration
• Low Volume: Soft tooling and flexible processes for pilot programs (50-5,000 pieces)
• Medium Volume: Steel rule dies for cost-effective production (5,000-50,000 pieces)
• High Volume: Automated punch press and optimized tooling (50,000+ pieces)
• Design Changes: Tooling modifications to accommodate engineering changes

Why Packaging Designers Choose DDC-Omni

• 70+ years of foam and rubber fabrication expertise
• Deep understanding of packaging engineering requirements
• Extensive material library with technical data sheets
• In-house tooling capabilities for rapid development
• Collaborative approach to design optimization
• Scalable production from prototype through millions of pieces
• Quality systems that support your supply chain requirements
• Technical support team that speaks your language
• Competitive pricing with transparent quoting
• On-time delivery performance you can depend on

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