Custom Packaging Inserts

Custom packaging inserts made to your size with no minimum order. Inserts are the fitted pieces that hold your product still inside the box, the difference between a clean unboxing and a rattling mess. Paperboard inserts, foam inserts, corrugated partitions, and molded pulp, cut to cradle your exact product. They protect fragile items in transit, present a gift set neatly, and make a plain box feel considered. We design the insert around your product dimensions so the fit is snug. No minimum order, free design help, free samples, and a fast turnaround. Send your product and its box, and we will send a free quote on inserts that fit.
Related packaging: rigid boxes, mailer boxes, retail packaging.
Choosing the insert material
Corrugated inserts are cut and folded from the same board as the box, which keeps the pack recyclable in one stream and costs least. Foam holds fragile or oddly shaped items in a fixed position and absorbs shock, and comes in different densities depending on weight. Molded pulp is formed to the product shape, is fully recyclable, and suits high volume where the tooling is worth it. Paperboard platforms and dividers suit light retail goods where the job is presentation rather than protection.
Protection or presentation
These are two different briefs and they lead to different inserts. If the job is protection, the insert has to stop the product touching the wall of the box and stop it moving in transit, which means clearance on every face and enough material to absorb a drop. If the job is presentation, the insert holds the product square to the eye at the moment the lid comes off, and the finish of the insert matters as much as its fit.
Tolerance and fit
An insert cut to the exact product dimension will not accept the product. Every material needs a small allowance, and how much depends on the material and how the product is loaded. Foam compresses and can be cut tighter. Corrugated does not, so it needs more clearance. We build the tolerance in rather than leaving you to discover it on the packing line.
What to send
Send the product dimensions, the weight, how many units go in one box, and whether a person or a machine is loading it. A sample product is better still. We will design the insert around it, send a free digital proof, and send a physical sample so you can test the fit before committing to a run.