Custom Box Inserts
Custom packaging inserts that protect your product and upgrade the unboxing experience. We manufacture die-cut cardboard trays (±0.5mm tolerance), EVA foam inserts (CNC-routed to your product contour), corrugated divider grids for bottle shipping, and molded fiber trays from recycled pulp. Multi-level platforms for gift sets with mixed product heights. 3D-modeled to your exact box and product dimensions, with a free physical prototype for fit testing. From 500 units.
Insert & Tray Types
Die-Cut Cardboard Insert
Precision die-cut from 18–24PT SBS board. Folds into multi-level trays. Holds bottles, tubes, and jars in exact position. Most cost-effective insert type.
Corrugated Divider Grid
Interlocking E-flute or B-flute dividers creating individual cells. Ideal for bottles, candles, and fragile items shipping in bulk. Available in 4, 6, 12, and 24-cell configurations.
EVA Foam Insert
Closed-cell EVA foam CNC-routed to match your product contour within 0.5mm tolerance. Provides maximum shock absorption. Used for electronics, glass, and high-value items.
Molded Fiber Tray
Thermoformed from recycled paper pulp. Fully compostable. Contoured to product shape. Used by Apple, Bose, and premium electronics brands. MOQ 2,000 for custom tooling.
Folded Platform Insert
Single sheet scored and folded into a raised platform or pedestal. Creates a 'floating' product presentation inside the box. Popular for luxury cosmetics and jewelry.
Friction-Fit Sleeve
Inner sleeve that wraps the product snugly. Slides in and out of the outer box for a premium reveal effect. Printed interior option for branded unboxing experience.
Packaging Inserts FAQ
What is the cheapest type of packaging insert?
Die-cut cardboard inserts are the most cost-effective — starting at $0.05–0.12/unit at volumes of 1,000+. They're cut from the same SBS board as your box (no separate material cost) and can fold into multi-level trays. Corrugated grid dividers are the second cheapest at $0.08–0.15/unit. Foam and molded fiber are premium options starting at $0.25+/unit.
Can inserts be made from the same material as the box?
Yes, and we recommend it. Using matching SBS board for both the box and insert creates a seamless look, simplifies recycling for consumers (single-material), and reduces cost since both run on the same production line. We can match the insert color to your box interior — white, kraft, or custom-printed.
How precise are die-cut inserts for product fit?
Cardboard die-cut inserts hold ±0.5mm tolerance — tight enough for most consumer products. EVA foam CNC routing achieves ±0.3mm. For products that need exact-fit (like electronics), we create a 3D model from your product dimensions and send a physical prototype for fit testing before production. Two prototype rounds are included free.
What is the minimum order for custom inserts?
500 units for die-cut cardboard inserts (same MOQ as boxes — we often produce both together). Corrugated dividers start at 500 units. EVA foam inserts start at 300 units. Molded fiber trays require 2,000 minimum due to custom tooling costs (~$800–1,500 for the mold).
Do you design inserts to match our existing boxes?
Yes. Send us your box dimensions (or the box itself) and the products that go inside. We 3D-model the insert to fit your exact box interior and product dimensions. The design process takes 2–3 business days and includes 2 revision rounds, a 3D render, and a physical prototype shipped to you for approval.
Can inserts hold multiple products at different heights?
Yes. Multi-level die-cut inserts use a stepped platform design — taller items sit in deeper cutouts while shorter items sit on raised platforms. We can accommodate 2–4 different product heights in a single insert. Common for gift sets, skincare kits, and subscription boxes with mixed product sizes.
Get a Custom Insert Prototype
Free 3D model, fit testing, and physical prototype shipped to you.