Hundreds of Materials 


Our packaging development process defines solutions that ensure optimal part protection.  We consider dunnage to be one of our specialties because we understand the delicate balance between design and cost-effectiveness. PCD sources from more than 750 material manufacturers, so we have access to a variety of materials and can offer you the best packaging solutions for supply chain optimization.



Sewn Internal Dunnage is used to protect class "A" surface parts, such as door panels, headliners and other large injection molded pieces. This returnable sewn bag system conforms to the contours of complex parts resulting in improved packaging density and reduced packaging costs for our automotive clients. They come in several material types including Vintex, Tyvek, Nylon, Vu Thru, and Spun Bond and can be installed into pallet boxes, handheld totes, and custom metal racks.



Plastic corrugated is offered in several thicknesses and can be manufactured to any size.  Standard profile is manufactured from high-density polyethylene and polypropylene plastic and is often employed as a divider for parts that must be separated to avoid scratching and marring. It can also be laminated with various materials for class "A" surface protection.  Plastic corrugated is ideal for harsh environments featuring moisture, electrostatic discharge “ESD” and humidity. Plastic corrugated is offered from 2mm - 10mm thicknesses. Laminates are offered in XLPE, Polyspun, and Tyvek.



Used for dunnage in steel racks to protect metal products and heavy parts. It is made from cast urethane and foamed urethane. This commodity-type dunnage must be used strategically as it typically has a higher cost. However, we know how to incorporate this material into a design and when it will be the most cost effective for our customers.



Polyurea is typically used in steel racks and standard containers. It can be sprayed directly on steel racks to protect them from scratching. It is a low volume alternative to injection molded dunnage. We have the ability to source polyurea at very competitive prices, to the benefit of our customers.



Solid sheet CNC dunnage is used to protect metal parts with sharp edges during shipment and when plastic corrugated may not be durable enough. We have the ability to assemble cell dividers.



Vacuum form dunnage is used in steel racks and trays stacked on pallets. It is usually used to support heavy parts. Vacuum form trays are reusable trays that can be customized to any dimension and thickness. They can be constructed of HDPE, ABS, HIPS, PET materials. High gauge trays are often used to house engine and transmission components, among other heavy/large parts that require improved stability. Lower gauge vacuumed formed trays are used to protect and transport parts that require individual protection.



Injection molded dunnage is used in steel racks and trays stacked on pallets or inside containers. It is typically used for heavy parts and in automation due to its ability to hold tight tolerances. It is also used in corrugated export packs from engines and transmissions.



Molded pulp is packaging typically manufactured from recycled paperboard and/or newsprint. It is used for protective packaging, food service trays, beverage carriers, end caps, trays, plates, bowls and clamshell containers. Pulp products generally have wall thicknesses of 3/16" to 1/2" and is viewed as an economical solution compared to more expansive expanded polystyrene (EPvacuumumed formed PET and PVC, corrugate and foams.



EPP is used for dunnage in steel racks and on pallets. It is usually used for parts with complicated contours. This product is best for high volume products. This product is most often expendable with limited returnable options


Molded foam is made from flexible polyurethane and functions as cushioning for products in transport. Typically, “high compliance” industries, like healthcare, the military, transportation industries and retail benefit from this product.  Molded foam shapes and contours to nearly any shape, it is low cost, consistent and has increased upholstering efficiency.


Foam and Cushioning Materials

  • Polyethylene: Polyethylene is the most popular polymer and can be molded as well as fabricated. It is often used due to its resistance to moisture and durable nature. It can also be recycled.


  • EVA Polyethylene: EVA is an elastomeric polymer that produces a “rubber-like” material.  It is UV radiation resistant, stress-crack resistant and has waterproof properties.


  • VCI Polyethylene and Paper: VCI Packaging, or Volatile Corrosion Inhibitor packaging film, protects metals from corrosion by forming a thin, invisible layer on the surface. This inhibits corrosion or rusting caused by oxygen, water, and other contaminants.


Dunnage can be made from any of the below materials or any combination thereof:


  • Plastic injection molded

  • 3D printed plastic

  • Vac-form

  • Foam

  • Vinyl

  • Urethane

  • Spray Urethane

  • Corrugated

  • Molded pulp

  • Molded Foam

  • Plastic Corrugated

  • Sleeve Packs

  • Wood

  • Anti-static Materials