Packaging Structure Design Corrugated Inner Support Product Custom Printing

Custom box inserts, also known as packaging inserts or packaging inlays, are used to ensure your products are secure inside your box. These can come in the form of paper inserts, cardboard inserts, or foam inserts. Other than product protection, custom inserts allow you to present your products beautifully during the unboxing experience. If you have multiple items in one box, packaging inserts are a great way to position each product just the way you’d like. What’s better is that you can fully customize each box insert with your branding! Take a look at our box insert guidelines, or simply get inspired with a selection of ideas for box inserts.

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Product Video

We have created a video tutorial on how to assemble double plug and airplane boxes. By watching this video, you will learn the proper assembly techniques for these two types of boxes, ensuring that your products are perfectly packaged and protected.

Common Insert Structures

With custom box inserts, there's no 'one size fits all'. The size, weight, and position of products all affect how the insert needs to be structured to secure each product. For reference, here are some examples of common insert structures.


Box Insert (No Backing)

Most commonly used for products that can sit directly at the base of the box and don't need to be elevated. These types of inserts are also ideal for products of the same size.


Box Insert (With Backing)

Most commonly used for products of the same/similar size that need to be elevated in order to fit securely in the insert. Otherwise, the products will fall through.


Box Insert (Multiple Backings)

Most commonly used for products of different sizes that need to be elevated in order to fit securely in the insert. Each backing is tailored to the size of the product and ensure they don't fall through the insert.

An Upgraded Unboxing Experience

Fully customizable

Customize your paper and cardboard inserts with full print and designs that pair beautifully with your boxes.

 MOQ from 300 units

Minimums starting from 300 units per size or design when ordered with the outer box. Standalone box inserts start with an MOQ of 500 units.

 Sturdy and secure

Custom box inserts are tailored to the precise size of your products, keeping them secure in transit while giving your customers a truly elevated unboxing experience.


Structurally Engineered to Perfection

Creating the optimal insert design requires more than meets the eye. Products come in various shapes, sizes, and weights, which means using the right materials, creating structures to securely hold each product, and ensuring the insert fits precisely with the outer box.

Most brands don't have a structural design team, which is where we can help! Start a structural design project with us and we'll help you bring your packaging vision to life.


Technical Specs: Custom Box Inserts

Corrugated Materials

Box inserts that are corrugated (the wavy lines in cardboard) are stronger and ensure the insert is sturdy. Corrugated inserts are typically used for heavier items, fragile items, or items that will be shipped and need extra cushioning/protection.


Most commonly used option and has a flute thickness of 1.2-2mm.


Ideal for large boxes and heavy items, with a flute thickness of 2.5-3mm.

Designs are printed on these base materials which is then glued to the corrugated board. All materials contain at least 50% post-consumer content (recycled waste).

White Paper

Clay Coated News Back (CCNB) paper that's most ideal for printed corrugated solutions.

Brown Kraft Paper

Unbleached brown paper that is ideal for only black or white print.

Non-corrugated Materials

Box inserts that are paper based and not corrugated are typically used for lightweight, non-fragile items. These paper based inserts used a standard thickness of 300-400gsm, and contain at least 50% post-consumer content (recycled waste).

White Paper

Solid Bleached Sulfate (SBS) paper that yields high quality print.

Brown Kraft Paper

Unbleached brown paper that is ideal for only black or white print.

Box inserts can also be made of foam, which are best for fragile items such as jewelry, glass or electronics. However, foam inserts are the least eco-friendly and cannot be printed on.

PE Foam

Polyethylene foam resembles a sponge-like material. Available in black or white.

EVA Foam

Ethylene Vinyl Acetate foam resembles a yoga mat material. Available in black or white.


All packaging is printed with soy-based ink, which is eco-friendly and produces much brighter and vibrant colors.


CMYK is the most popular and cost effective color system used in print.


For accurate brand colors to be printed and is more expensive than CMYK.


Coating is added to your printed designs to protect it from scratches and scuffs.


An eco-friendly water-based coating but doesn't protect as well as lamination.


A plastic coated layer that protects your designs from cracks and tears, but not eco-friendly.


Top off your packaging with a finish option that completes your package.


Smooth and non-reflective, overall softer look.


Shiny and reflective, more prone to fingerprints.

The Order Process for Custom Box Inserts

A 7 step process to designing and ordering custom box inserts.

Structural design

Structural design

Start a structural design project with us to receive an insert and box design that's been tested to fit your products.


Purchase a sample (optional)

Get a sample of your mailer box to test size and quality before starting a bulk order.


Get a quote

Go to the platform and customize your mailer boxes to get a quote.


Place your order

Choose your preferred shipping method and place your order on our platform.


Upload artwork

Add your artwork to the dieline template we'll create for you upon placing your order.


Start production

Once your artwork is approved, we'll start production, which typically takes 12-16 days.


Ship packaging

fter passing quality assurance, we'll ship your packaging to your specified location(s).

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