Custom electronics packaging is a printed box sized to the device and its accessories, with a fitted insert that stops the product moving. For a fragile or high-value device, pair a rigid or corrugated outer box with a foam or paperboard insert, and use anti-static material if you ship exposed circuit boards. We make these with no minimum order.
Reviewed by the TBPB packaging team, October 2026.
| Quick facts | Answer |
|---|---|
| Minimum order | None. Order one or ten thousand |
| Typical build | Outer box plus fitted insert |
| Insert choices | Foam or paperboard. Ask us to confirm for your spec |
| Bare circuit boards | Use anti-static (ESD) material |
| How to size | Device and accessories laid out, plus insert thickness and clearance |
| Quote and dieline | Free from the quote form |
What kind of outer box does an electronics product need?
It depends on how the product travels and how it is sold. A retail box needs good print and a clean opening. A shipping box needs strength and a fit that survives drops. Many brands use both: a printed retail carton inside a plain corrugated shipper.
| Outer box | Best for | Trade-off |
|---|---|---|
| Rigid box | Premium devices, gift sets, unboxing | Bulkier and heavier to store |
| Corrugated box | Shipping and heavier items | Less refined print than paperboard |
| Mailer box | Direct-to-customer shipping of lighter devices | Needs an insert for anything fragile |
| Folding carton | Lightweight retail items | Limited protection by itself |
For rule-of-thumb comparisons of these board types, see our article on corrugated, cardboard and rigid boxes. Browse the electronics packaging page for the range we make.
Foam or paperboard: which insert should I choose?
Choose by what the device weighs and how fragile it is. Foam grips a device in a cut cavity and absorbs shock, so it suits heavier or delicate electronics. A paperboard insert is lighter, prints well, and is easier to recycle, so it suits lighter, sturdier items such as cables, small accessories or a device in a hard case. If the box ships through the post, lean toward foam for glass screens or exposed parts.
Our custom box inserts guide compares the options, and you can look at custom foam inserts, paper inserts and custom boxes with inserts. Ask us to confirm which material and cavity style suit your spec.
When do I need anti-static packaging?
When the product is a bare board, a loose component or any part with exposed circuitry, because ordinary materials can build a static charge that damages chips. A finished device with a closed housing is usually fine in a standard insert. If your engineer specifies ESD protection, tell us before we quote so the right material goes into the spec. We do not make claims about specific ESD standards here. Confirm those with your engineer and with us in writing.
How do I size an electronics box? A worked example
Suppose a kit holds a small tracker (2.5 x 2.5 x 0.5 inches), a coiled cable (3 x 2 x 0.5 inches) and a quick-start card (4 x 3 inches, about 0.1 inch thick).
| Dimension | Working | Inside size |
|---|---|---|
| Length | 2.5 tracker + 0.25 divider + 3 cable + 0.25 clearance | 6.0 in |
| Width | Card is 3 wide, add 0.25 clearance | 3.25 in |
| Height | 0.5 device + 0.25 insert floor + 0.1 card + 0.25 clearance | about 1.125 in |
The order is 6 x 3.25 x 1.125 inches inside, with the tracker and cable seated in side-by-side cavities and the card lying on top. Check the cavity depth against the real device before approving, because a cavity cut too tight makes the device hard to lift out and a loose one lets it shift. Order one sample box and test it, including a closed-box shake.
What about batteries and heavier products?
Devices with lithium batteries have their own transport and labeling rules, and those rules sit outside what packaging alone can solve. Check the current carrier and regulatory requirements for your product before you finalize the box, and tell us if a label or marking area must be left clear. For heavier products, such as a speaker or a power station, move to double-wall corrugated or a rigid box with a thick insert, and test the pack with a real drop from the height a delivery driver would carry it. Ask us to confirm board options for the weight you have.
How much of the print budget should go on the box?
For a device that sells on its own shelf, a clean, readable front panel and a clear spec list do more than an elaborate finish. For a premium product that customers photograph, the opening matters more: a lid that lifts slowly, a device sitting in a cavity, and a card on top. Put your effort where the buyer is looking.
What do I not recommend?
Leaving the cavity loose around a fragile device and filling the gap with paper. It looks fine on the packing bench and fails in a parcel. Also avoid choosing the thinnest board to save money on a heavy device. Spend on the insert and the outer board first, and decorate second.
Questions buyers ask
What packaging protects electronics best?
A fitted insert inside a rigid or corrugated box. The insert holds the device still so it cannot shift or take a hit, and the outer box handles stacking and transit. For bare circuit boards, use anti-static material so static cannot damage components.
Do I need anti-static or ESD packaging?
It depends on the product. Exposed circuit boards and bare components need anti-static (ESD) foam or bags, because ordinary foam can build a static charge. A fully enclosed consumer device in its housing can usually go in a standard insert. Check with your engineer if unsure.
Is foam or a paperboard insert better for electronics?
Foam holds a device more firmly and absorbs more shock, so it suits heavier or more fragile items. A paperboard insert is lighter, prints well and is easier to recycle, which suits light, sturdy items. Choose by weight and fragility, not looks.
How do I size an electronics box?
Lay out everything that goes in: the device, cable, adapter, manual. Measure the layout, add the insert thickness and a small clearance, and order by inside size. Measure the device itself first, because the cavity must match it closely.
Is there a minimum order for custom electronics boxes?
No. We make custom electronics boxes and inserts with no minimum order, so a hardware brand can test a prototype run before committing to volume. Unit cost is higher at low quantity and falls as the order grows.
How do I get a quote and dieline?
Send the device dimensions and weight, what else goes in the box, and the quantity, even one, through the quote form. We return a dieline and a written quote. Hold a written quote for the same specs and we beat it.
How to order
Send the device dimensions, its weight, what else goes in the box and the quantity through the quote form. One box is a valid order, and there is no minimum. We reply with a dieline and a written quote. Bring a written quote for the same specs and we beat it. Design help, samples and shipping are free.
What packaging protects electronics best?
A fitted insert inside a rigid or corrugated box. The insert holds the device still so it cannot shift or take a hit, and the outer box handles stacking and transit. For bare circuit boards, use anti-static material so static cannot damage components.
Do I need anti-static or ESD packaging?
It depends on the product. Exposed circuit boards and bare components need anti-static (ESD) foam or bags, because ordinary foam can build a static charge. A fully enclosed consumer device in its housing can usually go in a standard insert. Check with your engineer if unsure.
Is foam or a paperboard insert better for electronics?
Foam holds a device more firmly and absorbs more shock, so it suits heavier or more fragile items. A paperboard insert is lighter, prints well and is easier to recycle, which suits light, sturdy items. Choose by weight and fragility, not looks.
How do I size an electronics box?
Lay out everything that goes in: the device, cable, adapter, manual. Measure the layout, add the insert thickness and a small clearance, and order by inside size. Measure the device itself first, because the cavity must match it closely.
Is there a minimum order for custom electronics boxes?
No. We make custom electronics boxes and inserts with no minimum order, so a hardware brand can test a prototype run before committing to volume. Unit cost is higher at low quantity and falls as the order grows.
How do I get a quote and dieline?
Send the device dimensions and weight, what else goes in the box, and the quantity, even one, through the quote form. We return a dieline and a written quote. Hold a written quote for the same specs and we beat it.
