Custom packaging inserts are the fitted pieces that hold a product still inside its box: foam, corrugated, and paper inserts cut to your product’s dimensions. Brands order them for fragile goods, gift sets, and kits where several items each need their own pocket. There is no minimum order, so one prototype insert is as easy to request as a full run, and if you bring a written quote for the same specs, we beat it. Start with custom foam inserts for fragile or oddly shaped items, paper inserts for lightweight retail kits, or the general custom packaging inserts page if you are not sure which material fits yet. Send the product dimensions and a quantity, and we build the insert around them.
Foam is the material for protection. Polyethylene and EVA foam can be cut to cradle a specific object, absorb shock, and keep its shape after repeated use, which is why it shows up around glass, electronics, instruments, and tools. If the product is fragile, start with custom foam inserts.
Corrugated inserts are folded or die-cut from the same family of board as a shipping carton. They suit sturdy products, they can be recycled in one stream with the outer box, and they work well as dividers between bottles or jars. They hold position better than they cushion.
Paperboard inserts are the lightest option and the most printable. They are the usual choice for retail kits, gift sets, and presentation trays, where the goal is a tidy reveal rather than shock absorption. See paper inserts for that format.
The insert is only as good as the measurements behind it. Measure the product at its widest points in length, width, and height, and measure the inside of the box, not the outside. Box walls and any lining take up space, and that is where most poorly fitting inserts go wrong.
A good cavity is snug enough that the product does not shift when you shake the closed box, and loose enough that you can lift the product out without prying. For soft or compressible items such as tubes and pouches, a slightly smaller cavity grips better. For rigid items with sharp corners, leave a little clearance so the corners do not chew into the insert. If the kit has several pieces, tell us which one should be seen first, because that decides the layout.
Foam is usually black, white, or gray. Black reads as premium under a lid and hides dust, white looks clean around cosmetics and medical items. Paperboard and corrugated inserts can carry printing and the same coatings as the box, which matters if the insert is the first thing a customer sees. If the insert sits under the product and is only structural, plain board is fine.
If the product only needs a snug container and nothing inside it needs to be separated, a correctly sized box often does the job without an insert at all. For shipped orders, pair the insert with shipping boxes or mailer boxes. For general cartons, look at cardboard boxes.
Send the product dimensions, a photo or the product itself if you can, the box it goes in, and a quantity. The quantity can be one. We come back with a dieline and a quote, and you can adjust the layout before anything is cut.
No. There is no minimum order, so you can order one insert to test the fit or ten thousand for a launch. Smaller runs are common for prototypes and sample kits before a brand commits to a full quantity.
Foam, usually polyethylene or EVA. It absorbs shock and can be cut to the exact shape of the product. Corrugated and paperboard inserts hold items in place but offer less cushioning, so they suit sturdier or lighter goods.
Measure the widest length, width, and height of the product, then measure the inside of the box it will sit in. Send both sets of numbers. If the shape is irregular, a photo with a ruler beside it helps us plan the cavity.
Yes. A single insert can have several cavities of different sizes, which is how gift sets and kits are usually built. Tell us the products and which one should be visible first, and the layout is planned around that.
Paperboard and corrugated inserts can be printed. Foam comes in standard colors such as black, white, and gray. If the insert is visible when the box opens, printing or choosing the foam color is worth deciding early.
Order both together. Send the product dimensions and we size the box and insert as one system, so the fit is planned instead of patched. Mailer boxes and shipping boxes both pair well with custom inserts.
