Custom Packaging Inserts
Custom Packaging Inserts
Continue on our platform to customize your packaging, compare products, get samples and much more.
Precise, protective, pristine
Customizable Box Inserts
Tailored product fit
Choose the exact layout you need to keep your items beautifully organized. Custom-fit inserts prevent your products from shifting in transit while giving your customers a polished, professional unboxing.
Versatile insert materials
Protect your products with the right material for the job. Choose dense EVA foam to secure high-value items, soft PU foam for lightweight cushioning, or eco-friendly corrugated materials to keep your packaging sustainable.
Premium protection, low minimums
Get access to premium, retail-ready custom inserts with an accessible minimum order quantity starting at just 300 units.
Print quality
Unbeatable quality with offset printing
We use offset printers to ensure your branded packaging stands out. This method delivers sharp, high-quality prints with vibrant colors, avoiding any "dotted" looks.
Structural design
Perfectly Engineered Packaging Solutions
Creating an ideal insert design is more than meets the eye. Because products come in various shapes, sizes, and weights, it becomes crucial to use the appropriate materials, construct robust structures to securely accommodate each item, and ensure a precise fit between the insert and the outer box to complete the package.
No need to hire an in-house packaging engineer or buy expensive equipment. Through our structural packaging design service for inserts, we'll help bring your product vision to life.
Common Insert Structures
With custom box inserts, there's no one size fits all solution. The structure of an insert is tailored to accommodate the size, weight, and position of each product, ensuring optimal security. Here are some examples of common paper or cardboard based insert structures:
- Box Insert (no backing): typically 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): typically used for products of similar sizes that need to be elevated to fit securely in the insert, or need extra support.
As part of the structural design process, our team will help determine the best insert structure for your products.
Successful customer projects for custom inserts
Designed to cradle your products perfectly, custom box inserts are the ultimate choice for secure transit, multi-product kits, and organized retail presentation. They are ideal for cosmetics, electronics, and fragile items looking to elevate both structural protection and interior aesthetic value. Available in precise foam, corrugated, and paperboard layouts, explore how brands use custom inserts to position each item beautifully and deliver an unforgettable unboxing experience.
Hear what our clients have to say
Bluecorn Beeswax
PackMojo is now our go-to for custom corrugated boxes! From packaging development through production, freight and quality assurance, their project management, expertise and professionalism are simply unmatched. Plus, they offer a wide variety of recycled and eco-friendly materials, in addition to a tree planting program. Highly recommend!
Rusty's Pet Essentials
Working with PackMojo was an absolute breeze. It can be intimidating working with a company overseas but Vincent helped me execute my project perfectly. The final custom boxes and inserts are incredible!
Aenomaly Constructs
Working with Wendy and the PackMojo team has been a dream. Very fast response time, detailed, and accurate. Could not be happier with the service and the packaging. Highly recommend!
Custom box insert order process
A single platform to get quotes and place orders, with dedicated support every step of the way.
Customize your packaging
Go to the PackMojo platform to customize the size, materials, print, and finishes of your inserts.
Get estimates & start structural design
Get price estimates of your inserts before starting on a structural design project, where we construct the perfect insert for your products.
Place your order
Place your production order once the insert structure is approved. Choose a preferred shipping method and even set up split shipments to get some packaging delivered quicker.
Upload artwork
Add your artwork to the dieline template that we tailor make to your box specifications.
Track order progress
Get full visibility on the progress of samples, production, and shipping.
Technical Specs: Custom Box Inserts
An overview of the standard customizations available for custom box inserts.
Corrugation
Corrugation, also known as flute, is used to strengthen the cardboard used in your packaging. They typically look like wavy lines which when glued to a paperboard, forms the corrugated board.
- E-flute
Most common choice. Flute thickness of 1.2–2mm.
- B-flute
Best for large boxes and heavy items. Flute thickness of 2.5–3mm.
Materials
Paperboard inserts without corrugation use a standard paper thickness of 300-400gsm. These materials contain at least 50% post-consumer content (recycled waste).
Foam packaging inserts are designed to keep products safe and secure during transportation. They are customizable, providing a snug fit that protects fragile or delicate items from potential damage.
- White SBS
Solid Bleached Sulfate (SBS) paper. Ideal for vibrant, high-quality full-color printing.
- Brown Kraft
Unbleached brown paper. Best suited for simple black or white designs.
- PU Foam
Open-cell Polyurethane foam is softer and more flexible, resembling the material of a sponge. Available in black or white.
- EVA foam
Closed-cell Ethylene Vinyl Acetate foam is more rigid and dense than open cell foam, resembling the material of a yoga mat. Available in black or white.
Color systems
All packaging is printed with soy-based ink, which is eco-friendly and produces much brighter and vibrant colors.
- CMYK
Cost-effective, standard full-color printing system.
- Pantone
Premium color system used for exact brand color matching.
Coating
Coating is added to your printed designs to protect it from scratches and scuffs.
- Varnish
An eco-friendly, water-based protective layer.
- Lamination
A plastic layer that protects against scuffs, cracks, and tears.
Finishes
Top off your packaging with a finish option that completes your package.
- Matte
Smooth, non-reflective, softer look
- Glossy
High-shine reflective finish.
- Satin
Semi-shiny blend between matte and glossy.
- Soft touch
Premium matte look with a velvet-like texture.
Add-ons
Enhance your packaging designs with specialized printing treatments and accents.
- Foil stamping
Metallic or colored foil layer applied with heat for a reflective shine.
- Spot UV
Glossy coating applied to specific areas for high-contrast texture.
- Embossing
Raised design pressed into the material to create a distinct, 3D texture.
- Debossing
Depressed design stamped into the material for a recessed, indented effect.
Samples
Looking to try a sample first?
Get your hands on a selection of our most popular boxes and packaging with a reimbursable sample kit.
Frequently Asked Questions
Can't find what you're looking for? Check out our help center.
What is the minimum order quantity for custom box inserts?
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.
Where is your packaging produced?
We manufacture all of our packaging through a vetted network of trusted production partners in China, and ship everything directly from the factory to your doorstep.
What are your lead times?
Our standard production lead times typically take 12-16 days, though larger bulk orders can take 3-4 weeks depending on the overall volume and complexity of your packaging. Total delivery timelines will vary based on the shipping method you select.
How long does shipping take?
Shipping times depend entirely on the transport method you choose for your packaging. Air freight generally takes 1-3 weeks, while ocean freight ranges from 4-8 weeks. If you are on a tight deadline, you can split your shipment to send an initial batch via air and the remainder by sea.
How do I get a quote for inserts?
Log in to the PackMojo platform to input your box and insert specifications and submit a quote request. Our team will review your requirements and get back to you with an estimated quote. You can then consider proceeding with a structural design service where we'll design the perfect insert structure that fits your products.
Can you provide me with a custom box insert dieline?
Dielines are provided as a deliverable of our structural design service.
Can I get a sample of my insert?
As long as we have the final insert dieline (either through our structural design service or by sending us your existing one), you can purchase a sample of the insert. More info on sample options here.
What format should I provide my artwork to you in?
Please submit your artwork using the custom dieline template we provide, ideally in an editable PDF or Adobe Illustrator (AI) format. To ensure your file is production-ready, keep the design on a separate artwork layer and review our dieline design guide before uploading.
Get Custom Packaging Inserts Today
Continue to the PackMojo platform to customize your boxes and inserts and get an initial quote.