Custom Pallets
When standard sizes won't cut it, our fabrication shop builds pallets to your exact specifications. Any dimension, any load capacity, any quantity — from 10 pallets to 10,000.
Our Tucson shop has built custom pallets for aerospace companies, copper mines, solar installers, craft breweries, military contractors, and dozens of other industries with non-standard needs. If you can describe what you need to carry and how you need to move it, we can engineer and build the pallet for it.
Request a Custom Quote
Our Custom Process
Consult
Tell us your dimensions, load requirements, material preferences, and quantity. We ask about your handling equipment, storage environment, and shipping method to design the optimal pallet.
Design
Our team creates a detailed spec sheet with lumber dimensions, nail patterns, and load-bearing calculations. For complex builds, we produce CAD drawings and prototype for your approval before production.
Build
Your pallets are fabricated in our Tucson shop using the specified lumber and construction methods. Every unit is built to the same spec — no variation between the first pallet and the last.
Deliver
We inspect every pallet before delivery and get them to your facility on schedule. Large orders can be phased across multiple deliveries to match your consumption rate.
Recent Custom Builds
Here are four recent custom pallet projects that showcase the range of what we build. Every project starts with a conversation about your needs and ends with pallets that perform exactly as specified.
Aerospace Wing Crate Pallets
Defense contractor, Tucson — 150 units
96" × 60" oversized hardwood pallets with 8,000 lb static load rating. Custom notched stringers for crane access. Anti-vibration rubber pads bonded to deck surface. ISPM-15 heat-treated for international airlift shipping.
Solar Panel Transport Platforms
Solar installation company, Southern AZ — 500 units (recurring quarterly)
72" × 48" pallets with adjustable foam-lined dividers to hold 12 solar panels per pallet in vertical orientation. Beveled edges to prevent panel scratching. Lightweight SYP construction to stay under truck weight limits.
Brewery Keg Pallets
Craft brewery, Tucson — 200 units
48" × 48" block pallets with recessed deck slots to cradle half-barrel kegs and prevent rolling. Food-grade kiln-dried pine. Built-in collar attachment points for stackable collar system. 4-way entry for tight cold-storage access.
Mining Equipment Skids
Copper mine, Green Valley — 75 units
120" × 72" heavy-duty skids with 6×6 oak runners, 12,000 lb dynamic load capacity. Bolt-through construction (no nails) to withstand crane and heavy forklift handling. Pre-drilled tie-down anchor points on all four corners.
Engineering Capabilities
Custom pallets require more than just cutting wood to size. Our engineering capabilities ensure your pallets perform safely and reliably under real-world conditions.
Load Testing
We calculate static, dynamic, and racking load capacities for every custom design using NWPCA (National Wooden Pallet and Container Association) engineering standards. For critical applications, we build and physically test prototypes under load to verify performance before committing to a full production run. Test data is documented and provided with your order.
CAD Design
For complex custom pallets — especially those with integrated features like dividers, foam inserts, recessed slots, or multi-level decks — we produce detailed CAD drawings showing all dimensions, fastener locations, and material specifications. You review and approve the design before we cut the first board. Revisions are included at no extra charge.
Prototyping
Before committing to a large production run, we build 1–5 prototype pallets for you to test in your actual facility with your actual products and handling equipment. This catches fit, weight, and handling issues before they become expensive problems at scale. Prototype pallets are built on the same production jigs as your final order to ensure consistency.
Material Options Comparison
Choose the right lumber for your application. We offer Southern Yellow Pine, hardwood, and combination builds where hardwood stringers support softwood deck boards for an optimal balance of strength and cost.
| Property | Southern Yellow Pine | Hardwood (Oak/Maple) | Combo (HW + SW) |
|---|---|---|---|
| Cost (per 48×40 pallet) | $12 – $18 | $18 – $28 | $14 – $22 |
| Dynamic Load Capacity | 2,000 – 3,000 lbs | 3,000 – 5,500 lbs | 2,500 – 4,000 lbs |
| Static Load Capacity | 4,000 – 6,000 lbs | 6,000 – 10,000+ lbs | 5,000 – 8,000 lbs |
| Weight (48×40) | 33 – 48 lbs | 55 – 75 lbs | 40 – 60 lbs |
| Avg Lifespan (trips) | 8 – 15 | 15 – 30+ | 12 – 20 |
| Nail Holding | Good | Excellent | Good–Excellent |
| Moisture Resistance | Moderate | High | Moderate–High |
| Repairability | Easy | Moderate | Easy–Moderate |
| Best For | Standard loads, cost-sensitive | Heavy loads, long-life, reusable | Balanced performance & cost |
Industries We Serve
Aerospace & Defense
Oversized pallets for aircraft components, precision tolerances for automated handling systems. Crate-base pallets for sensitive avionics and missile components.
Automotive
Engine block pallets, door panel racks, and custom stillages for auto parts logistics. Returnable pallets designed for closed-loop supply chains between plants.
Manufacturing
Pallets sized to your production line footprint, built for forklift, conveyor, and ASRS compatibility. Work-in-progress platforms and assembly station bases.
Agriculture
Ventilated pallets for produce, heavy-duty pallets for crated goods, field-use pallets for irrigation equipment. Sizes matched to cold storage and cooler dimensions.
Construction
Heavy-load pallets for building materials, oversized pallets for sheet goods and lumber bundles. Disposable jobsite pallets and reusable yard pallets.
E-Commerce & Retail
Display pallets, quarter pallets for retail floor placement, lightweight pallets for parcel shipping. Custom sizes that maximize trailer cube utilization.
Customizable Specifications
Minimum Order Quantities
We accept custom orders starting at just 10 units. Here is how order size affects pricing and turnaround.
10–49 Units
Setup: Standard setup fee
Turnaround: 5–7 business days
Ideal for prototyping and testing a new pallet design before committing to volume. Per-unit cost is highest at this tier but you get the exact pallet you need without a large upfront investment.
50–199 Units
Setup: Reduced setup fee
Turnaround: 5–10 business days
The sweet spot for small businesses and seasonal needs. Setup costs are amortized over more units, bringing per-pallet pricing down 10–15% compared to the smallest tier.
200–999 Units
Setup: Setup fee waived
Turnaround: 7–15 business days
No setup fee at this volume. Production is scheduled in dedicated batches for maximum efficiency. Volume discount of 15–20% applies. Phased delivery available.
1,000+ Units
Setup: Setup fee waived
Turnaround: Custom schedule
Enterprise pricing with 20–30% volume discount. Dedicated production run, standing inventory option, and auto-replenishment programs available. We assign a dedicated account manager to your order.
Let's Build Your Perfect Pallet
Contact us with your specs and we'll provide a detailed quote within 24 hours. Include dimensions, load requirements, quantity, and any special features — or just describe what you need to carry and we will engineer the solution.