Inserts & ProtectionCustom Packaging
Custom Inserts & Protective Packaging That Keep Products Safe
Key Takeaways — Custom Inserts & Protection
MOQ
500 units
Lead Time
10-15 days
Printing
Full Color CMYK
Eco Options
FSC Certified
Shipping
Free Shipping
What Are Custom Inserts & Protection?
Product inserts and protective packaging prevent damage during shipping and create a structured unboxing experience. We manufacture die-cut corrugated inserts, molded pulp trays, EVA foam with fabric covering, paperboard dividers, and custom thermoformed plastic blisters — all engineered from your exact product dimensions using 3D CAD modeling.
Damage rates on shipped products average 6-8% without proper interior protection. Custom inserts reduce that to under 0.5%. The math is simple: if your product retails at $25 and you ship 10,000 units, a 6% damage rate costs $15,000 in returns and replacements. Custom inserts at $0.30/unit cost $3,000 — paying for themselves 5x over on the first production run.
Beyond protection, inserts organize the unboxing. Multi-component products (a bottle, a card, a tool) each nest into their own compartment. The customer opens the box and sees every item presented deliberately. We produce corrugated inserts from 500 units, molded pulp from 2,000 units, and foam inserts from 300 units. Production runs 7 to 14 business days.
Specifications
Detailed technical information for informed decisions.
Materials
- CorrugatedE-flute (1.5mm), B-flute (2.5mm), microflute (0.5mm)
- Molded PulpSugarcane bagasse, recycled paper, bamboo fiber
- FoamEVA 18-45 kg/m3, PE, EPE, polyurethane
- PlasticPET, PVC, PS thermoformed, 0.3-1.0mm gauge
Performance
- Drop ProtectionISTA 3A tested, 3ft+ drop heights
- CompressionUp to 150 lbs stacking load
- VibrationASTM D4728 random vibration tested
- Temperature-20°F to 160°F operating range
Fabrication
- Die CuttingFlatbed and rotary die cutting
- MoldingCustom aluminum mold tooling
- Foam CuttingCNC router, waterjet, hot wire
- Tolerances±0.5mm on all critical dimensions
Die-cut cardboard or foam inserts that cradle your product in the box. Premium presentation and protection.
Custom Box Inserts
CNC-cut or die-cut foam that cradles your product inside the box. Polyethylene, EVA, or polyurethane.
Foam Inserts
Keep bottles, jars, and fragile items separated inside the box. Cut to fit any layout.
Cardboard Dividers
Single or double-wall inserts that protect products during shipping. Custom die-cut to fit.
Corrugated Inserts
Egg-carton-style molded fiber inserts. Biodegradable protection for electronics, cosmetics, and food.
Molded Pulp Inserts
Shredded paper fill in 30+ colors. Adds volume and cushioning to gift boxes and mailers.
Crinkle Cut Paper Fill
Paper-based wrap that stretches into a honeycomb pattern. Protects fragile items, 100% recyclable.
Honeycomb Wrap
Branded packing slips with your logo, order details, and return instructions. Makes every shipment professional.
Packing Slips
Available Insert Formats
Custom inserts and cards to enhance your packaging experience.
Corrugated Die-Cut Insert
E-flute or B-flute corrugated board die-cut and scored into custom shapes. Folds into position inside the box creating compartments, platforms, and cradles. 100% recyclable. Starting at 500 units.
Molded Pulp Tray
Custom-molded from sugarcane bagasse or recycled paper pulp. Mimics the protection of EPS foam with a sustainable material. Smooth finish or natural texture. Home compostable. Starting at 2,000 units.
EVA Foam Insert
Thermoformed EVA foam die-cut to cradle products with millimeter precision. Available covered in velvet, satin, or microfiber fabric for luxury presentation. Starting at 300 units.
Paperboard Divider
SBS or kraft paperboard cut and scored into slotted divider grids. Separates bottles, jars, and cylindrical products inside shipping boxes. Flat-packed inserts interlock without glue.
Thermoformed Blister
Clear PET or PVC thermoformed plastic clamshell inserts. Custom cavities display products visually while providing impact protection. Common for electronics, cosmetics, and hardware.
Inflatable Air Packaging
Air-filled PE film cushioning that wraps or surrounds products inside shipping boxes. Lightweight alternative to foam peanuts. Custom-sized air pillows and wrap formats available.
Built With Quality
Detailed view of the materials we use.
E-Flute Corrugated
1.5mm thin-profile corrugated board ideal for lightweight product inserts. Die-cuts cleanly into intricate shapes with tight fold radii. 100% curbside recyclable. The most cost-effective insert material for products under 5 lbs.
EVA Foam
Ethylene-vinyl acetate closed-cell foam in densities from 18 to 45 kg/m3. Shock-absorbing, moisture-resistant, and dimensionally stable. CNC routed or die-cut to ±0.5mm tolerances. Optional fabric covering for luxury presentation.
Molded Sugarcane Pulp
Agricultural waste from sugar processing formed into custom protective trays under heat and pressure. Replaces EPS foam with equivalent shock absorption. Fully compostable. Smooth-finish option rivals thermoformed plastic in appearance.
SBS Paperboard
300-450gsm solid bleached sulfate board for printed dividers, platforms, and structural inserts. Clean white surface accepts full-color printing. FSC-certified. Cut and scored to fold into position without adhesive.
PET Thermoformed Tray
Clear PET plastic thermoformed into custom cavities for product display and protection. Transparent material shows products while holding them securely. 0.3-1.0mm gauge. #1 recyclable.
Printing & Finishing
Premium print methods and finishing options to make your packaging stand out.
Printed Corrugated Inserts
1-4 color flexo or digital printing on corrugated inserts. Print instructions, product placement guides, brand messaging, or decorative patterns directly on the insert surface.
Fabric-Covered Foam
EVA foam wrapped in velvet, satin, microfiber, or leatherette fabric. Choose from 40+ colors or Pantone-match to your brand. The premium option for luxury product presentation.
Branded Tissue Overlay
Custom-printed tissue paper placed over the insert as a top layer. Adds a branded reveal moment — customers lift the tissue to find products nested in precision cavities below.
Color-Matched Pulp
Molded pulp trays manufactured in custom colors using dyed fiber. Available in black, white, natural, and limited custom Pantone shades for brand consistency.
Insert Instruction Printing
Printed directional text and icons on the insert surface showing which product goes where. Essential for multi-component kits where assembly order matters.
UV Printing on Foam
Direct UV-cured inkjet printing on foam surfaces for logos, product SKUs, and alignment marks. Permanent, no additional covering needed.
Debossed Foam Logos
Brand logos pressed into the foam surface creating a recessed impression. Subtle, tactile branding visible when the box opens. Available on EVA foam 25mm and thicker.
Foil-Stamped Paperboard
Gold, silver, or custom foil applied to paperboard dividers and platforms. Adds premium metallic accents to the protective packaging layer inside the box.
Unlimited Customization
Every inch of your packaging can be customized to match your brand.
Multi-Tier Inserts
Stacked insert layers create a reveal experience — lift the top tray to discover additional products below. 2 and 3-tier configurations available in corrugated, foam, and pulp materials.
QR Code Integration
Printed QR codes on insert surfaces linking to setup instructions, video tutorials, or warranty registration. Eliminates separate instruction cards and adds digital engagement.
Velvet & Satin Flocking
Electrostatic flocking applies fine fabric fibers directly to insert surfaces. Creates a uniform velvet or satin texture in any Pantone color. Premium finishing for jewelry, watches, and luxury goods.
Custom Cavity Shapes
Insert cavities precisely match your product contour — from cylindrical bottles to irregular electronic components. 3D scanning ensures sub-millimeter fit accuracy.
Combination Materials
Hybrid inserts combining corrugated structure with foam cushioning zones. Rigid framework holds shape while foam absorbs impact at critical product contact points.
Reusable Insert Design
Inserts engineered for the customer to reuse — products slide in and out cleanly. Ideal for refillable cosmetics, tool sets, and subscription box programs.
From Idea to Impact
Get your custom packaging in 4 easy steps.
Share Your Product Dimensions
Send us your product (or its dimensions, weight, and fragility rating). We 3D-scan or CAD-model the exact shape including tolerances for manufacturing variation.
Engineering & Prototyping
Our structural engineers design the insert in 3D CAD, simulate drop and compression forces, and produce a physical prototype. You test-fit your actual product and approve.
Drop & Vibration Testing
Optional ISTA 3A testing simulates real shipping conditions. We verify the insert prevents damage from a 30-inch drop on all 6 faces, 3 edges, and 1 corner.
Production & Delivery
Manufacturing runs 7-14 business days. Inserts ship flat (corrugated/paperboard) or formed (foam/pulp). Delivered to your warehouse or directly to your co-packing facility.
Key Features & Benefits
Everything you need for premium custom packaging.
Under 0.5% Damage Rate
Custom-fit inserts cradle products at every pressure point. Reduces shipping damage from 6-8% industry average to under 0.5%. Pays for itself on the first production run.
3D CAD Engineered
Every insert is modeled in 3D CAD from your exact product dimensions. We account for tolerances, drop angles, and stacking forces. Physical prototypes included before production.
Multi-Component Nesting
Products with multiple parts — bottle plus card plus brush — each get their own custom cavity. Everything stays in place during transit and presents beautifully on opening.
Sustainable Options
Corrugated inserts are 100% curbside recyclable. Molded pulp inserts are compostable. Replace EPS foam and bubble wrap with equally protective, planet-friendly alternatives.
Trusted by brands in
Frequently Asked Questions
Why Order Inserts & Protection from Cubit?
A complete packaging platform — not just a printer. Design, order, track, and protect.
Not sure what you need?
Our AI Packaging Consultant can analyze your product and recommend the perfect specs in seconds.
Inserts & Protection
Custom Box Inserts
Die-cut cardboard or foam inserts that cradle your product in the box. Premium presentation and protection.
Inserts & Protection
Foam Inserts
CNC-cut or die-cut foam that cradles your product inside the box. Polyethylene, EVA, or polyurethane.
Inserts & Protection
Cardboard Dividers
Keep bottles, jars, and fragile items separated inside the box. Cut to fit any layout.
Inserts & Protection
Corrugated Inserts
Single or double-wall inserts that protect products during shipping. Custom die-cut to fit.
Inserts & Protection
Molded Pulp Inserts
Egg-carton-style molded fiber inserts. Biodegradable protection for electronics, cosmetics, and food.
Inserts & Protection
Crinkle Cut Paper Fill
Shredded paper fill in 30+ colors. Adds volume and cushioning to gift boxes and mailers.
Inserts & Protection
Honeycomb Wrap
Paper-based wrap that stretches into a honeycomb pattern. Protects fragile items, 100% recyclable.
Inserts & Protection
Packing Slips
Branded packing slips with your logo, order details, and return instructions. Makes every shipment professional.
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