Solutions / Thin Gauge / Electronics Trays / Server Inserts
Custom Thermoformed Server Shipping Inserts
Blue Ridge Thermoforming thermoforms custom inserts for 1U and 2U servers, a formed-plastic alternative to foam when a chassis needs repeatable support in a shipper.
Request a Quote1U server packaging and 2U server packaging often rely on a foam end cap. A thermoformed insert can do that job: a cavity that follows the chassis face, the ears, and the rail, and that can be reused.
This is the foam-alternative server insert. Component trays for the CPUs, memory, and drives inside the chassis are separate pages. We form the plastic. We do not crate or freight the server.
Support formed to the chassis
1U and 2U profiles
Pocket height follows the chassis you send. A 1U insert and a 2U insert are different tools when the face and depth differ.
Ears, rails, and ports
Relief for rack ears and connectors so the contact points are the ones you choose, not a random high spot on the bezel.
Reusable dunnage
Inserts are reusable and durable for a return loop between sites, warehouses, and repair benches.
Inside the shipper you already use
The insert drops into your carton or tote. We do not replace the corrugated box unless you also want a formed plastic shipper discussed from the sample.
Static-control materials
- HIPS, PET, and rPET selected for stiffness and reuse.
- Static-dissipative grades when the insert touches exposed electronics.
- Clear or black static-dissipative options are available when a lot needs visual inspection, alongside conductive materials for the most sensitive parts.
- Thin-gauge trays are reusable and durable for repeated handling, stacking, and shipment.
Chassis moves between sites
- Sample the 1U or 2U chassis, including rails if they stay on
- Fit-check the insert in your shipper
- Pair with component trays when the chassis is stripped
- Production runs at low or high volume under ISO 9001:2015 quality processes, made in Greenville, SC.
The chassis insert and the component trays
Some shipments move a whole server. Others move the parts after it is stripped. Server shipping packaging on this page is the insert for the chassis. Server component packaging is the tray set for the parts.
Send a chassis sample or a drawing with the shipper constraints. We will quote the insert. Laptop and mini PC inserts are a smaller version of the same idea.
If rails stay on the chassis in transit, include them in the sample. A rail changes the width the insert has to clear, and a bezel-only sample will not show that. The fit-check happens in the shipper you already use.
Server Shipping Insert FAQs
Do you replace foam end caps?
Yes. The thermoformed insert is a foam alternative, tooled to the 1U or 2U chassis you send.
Can the same insert be reused?
Yes. Inserts are reusable and durable for repeated handling between sites.
What are your minimums and lead times?
Depends on part and volume. Send your counts and we'll quote it.
Quote a server shipping insert
Send a 1U or 2U sample, or a drawing, and we will quote an insert built for that chassis.