Structural Design for Packaging

Structural Design Service

Some packaging types such as custom box inserts or uniquely shaped packaging require structural engineering to be brought to life. That's why we offer a range of comprehensive structural design packages tailored to meet your unique needs. Our team of expert engineers will create custom box insert structures that perfectly fit your products, ensuring optimal protection and presentation. Choose the package that suits you best, and we'll help you create unboxing experiences your customers will love.

Why Structural Design for Inserts?

Creating the perfect structure for inserts goes beyond adding a few cutouts to a piece of paper. It involves key considerations, such as:

  • Choosing materials that ensure durability of the insert and keeping your products secure.
  • Creating an optimal insert structure that securely holds each item, accommodating variations in size, shape, and weight distribution.
  • Creating the outer box that fits the insert precisely, minimizing any material waste.

Our structural engineers will take all of these factors into account during the design process, providing you with a robust and reliable insert design.
Recanto Wellness Magnetic Rigid Boxes with Custom Box Inserts

Structural Design Examples

Here are some examples of different structural design projects we've worked on across various products and incorporating a variety of materials.

Custom Box Inserts for Product Sets
Structural Design
Box Inserts for a Set of Products
Custom Cardboard Packaging Insert
Structural Design
Kraft Box Inserts
Structural Design Packaging Insert and Rigid Box
Structural Design
Box Inserts for Electronics and Components
Custom Box Inserts for Glass Bottles
Structural Design
Box Inserts for Bottles
Custom Foam Insert
Structural Design
Custom Foam Inserts (PU)
Magnetic Lid Rigid Box with Inserts
Structural Design
Box Inserts for a Set of Glassware
Custom Box Partitions and Inserts in a Magnetic Rigid Box
Structural Design
Custom Box Inserts and Dividers
Foam Insert in Drawer Box
Structural Design
Custom Box with Foam Inserts

Service Packages

Choose the right structural design service package for your needs and let us bring your packaging vision to life.


The essentials to get you up and running with custom box inserts.

US$ 199
Get started
Structural design with 1 revision1 structural sample1 partial sample kitUS$ 59 reimbursed upon placing a production order
Most popular

Designed for those seeking a more in-depth and refined approach.

US$ 499
Get started
Structural design with up to 3 revisions1 structural sample1 sample kit1 press proofUS$ 199 reimbursed upon placing a production orderPackaging strategy consultation

A fully customized solution for unique or complex packaging requirements.

Get started
Structural design with up to 5 revisions1 structural sample1 sample kit1 pre-production sampleCustom reimbursement upon placing a production orderPackaging strategy consultation
Need more revisions?

Additional revisions or design time can be purchased on an hourly basis at a rate of US$ 99 per hour.

Structural Design Process

The structural design process is designed to be efficient and seamless, ensuring a smooth progression for your packaging project.


  1. Get estimated quote: Submit a quote request for your boxes and inserts on the platform. This will help us understand your project requirements and provide an estimated quote for the packaging and shipping costs.
  2. Choose service package: Choose the structural design service package that best suits your needs.
  3. Send your products: Send your products to our office for us to start the structural design process.

Design & Samples

  1. Structural design (7-10 days): After approval, we'll send a sample for you to test with your products.
  2. Structural sample (4-7 days): After approval, we'll send a sample for you to test with your products.
  3. Revisions (if required): You can request revisions to the insert design. Additional revisions and design time beyond your service package can be purchased by the hour.
  4. Printed samples (if applicable): We'll provide the dieline template for your artwork to be added. Lead times for printed samples can be found samples.


  1. Get final quote: We'll provide a final quote based on the approved packaging structure and latest specifications.
  2. Place production order: Place your production order and get a partial reimbursement on the paid service package.

Frequently Asked Questions

Why do I need to send my products to you?

Designing an insert structure that securely holds each product and accommodates variations in size, shape, and weight distribution is challenging without physical samples. Some products may require additional supporting structures, and without the actual products, achieving an optimal and snug fit to prevent product displacement becomes more difficult. By having the products on hand, we can ensure a customized and secure solution for your products.

What is a partial sample kit?

A partial sample kit consists of 1 or 2 examples of packaging that we've previously produced. It serves as a reference on the production quality for a similar product.

What are the differences between each sample?

Full descriptions of each sample type can be found here.

Can I purchase samples that aren’t included in my service package?

Absolutely! These will be charged at the same rate you see it here.

How long does the structural design process take?

Once we have your products on hand and the scope of the design is confirmed, it typically takes about 7 days for the initial design to be complete.

What is counted as a revision?

Revisions are any changes that were not discussed or considered within the initial discussion of the design. This includes modifications such as changing packaging types, material, size requirements, or the orientation and position of products. However, corrections needed to fix structural issues, such as adjusting the tightness of the lid, box closure, or insert cutout sizes, will not be considered as revisions.

How long do revisions take?

This depends on the scope of the revision. Smaller changes can be as quick as 2-4 days, and larger changes may take up to 7 days.

Get started today

Continue to PackMojo Pro to get a quote and select your preferred structural design package.