Custom Vape Boxes: Child-Resistant Packaging & Compliance Guide (2026)

Custom vape packaging operates in the most heavily regulated space in consumer goods. Between the PACT Act, FDA deeming regulations, state-level restrictions, and retailer requirements, getting your vape box wrong isn't just a branding mistake — it's a compliance violation that can result in fines, product seizures, and market bans.

This guide covers the intersection of compliance and creativity: how to build vape packaging that meets every regulation while still creating shelf presence and brand recognition in a crowded market.

Regulatory Landscape: What You Must Include

FDA Required Warnings

All nicotine-containing vape products must display the FDA nicotine warning: "WARNING: This product contains nicotine. Nicotine is an addictive chemical." This warning must cover at least 30% of the two principal display panels in specific font sizes. Non-compliance triggers Warning Letters and potential product removal.

PACT Act Compliance (2021+)

The Prevent All Cigarette Trafficking Act requires specific packaging for shipping vape products via mail: age verification labels, "CONTAINS TOBACCO" or "CONTAINS NICOTINE" external markings, and carrier-compliant packaging. This affects your outer shipper design significantly.

State-Level Requirements

Individual states layer additional requirements: California Prop 65 warnings, New York flavor ban labeling, and various state tax stamp accommodations. Your packaging design must accommodate these regional variations without requiring separate SKUs for each state.

Child-Resistant Packaging Mechanisms

Child-resistant (CR) packaging is federally required for liquid nicotine and increasingly required for all vape products at the state level. CR mechanisms include:

Push-and-Turn Lock Tabs: Integrated cardboard tabs that require simultaneous push-and-lift actions. The most common CR solution for folding cartons. Adds $0.15–$0.30 per unit.

Squeeze-and-Slide: Requires squeezing side panels while sliding open. More intuitive for adults but difficult for children under 5. Cost: $0.20–$0.40 per unit.

Button-Lock Closure: A recessed button that must be pressed while lifting the lid. Provides the most secure CR rating. Cost: $0.25–$0.50 per unit.

Printing Restrictions and Best Practices

Vape packaging design must balance brand identity with regulatory constraints:

• No cartoon characters or imagery appealing to minors — FDA actively enforces this restriction

• Warning text must be legible — minimum 9pt font on white or light background

• No misleading health claims — "safer than cigarettes" or "healthy alternative" triggers enforcement

• Flavor descriptions must be accurate — food imagery restrictions vary by state

Within these constraints, effective vape packaging uses bold typography, geometric patterns, metallic foils, and color-coded flavor systems. The brands winning shelf space use distinctive color palettes and structural differentiation (die-cuts, unique shapes) rather than imagery.

Material Options for Vape Boxes

18pt SBS (Solid Bleached Sulfate): The industry standard. Smooth white surface for high-quality printing. Supports all CR mechanisms. Cost: $0.80–$1.50/unit at 1,000 MOQ.

24pt SBS: Heavier board for premium feel and better CR mechanism integration. Recommended for disposable vape devices. Cost: $1.00–$1.80/unit at 1,000 MOQ.

Rigid Chipboard: For premium vape devices and starter kits. EVA foam inserts protect devices and batteries. Cost: $3.50–$7.00/unit at 500 MOQ.

Order Custom Vape Boxes from Cubit

At Cubit, we manufacture compliant vape packaging with integrated CR mechanisms. Our team reviews your design against current FDA and PACT Act requirements before production. MOQ: 100 units. Turnaround: 10–14 business days.

Get a free quote for compliant vape packaging.

FAQ

Do vape boxes need to be child-resistant?

Yes — all liquid nicotine packaging requires CPSC-certified child-resistant mechanisms under federal law (PCCSA). Many states extend this requirement to all vape products including devices and pods. Cubit offers three CR mechanism options built into our standard vape box designs.

What information is legally required on vape packaging?

At minimum: FDA nicotine warning (30% of principal display panels), net quantity, ingredient list, manufacturer information, and nicotine concentration. State requirements add Prop 65, flavor restrictions, and tax stamp areas.