Custom Box Inserts

What are custom box inserts?

Custom box inserts are the shaped pieces inside a box that hold each item in place. A good insert stops products from sliding, knocking together or turning upside down, and it makes the box look organized the moment it opens. Inserts are cut to your exact products, so a set of three jars, a perfume bottle or a phone accessory each gets its own fitted spot instead of loose filler.

Most brands order inserts with their boxes, because the insert and the box are sized together. They show up in gift sets, subscription boxes, cosmetics kits, candle sets, sample packs and anything with glass or several small parts.

Which type of packaging insert should I choose?

The right material depends on product weight, how fragile it is and how premium the unboxing needs to feel.

Card inserts suit most retail and gift boxes. Custom corrugated inserts and corrugated box inserts make more sense when the box ships by courier or holds something heavy, while molded pulp inserts cradle irregular shapes closely. A two-layer insert adds a top tray that lifts out to show a second level underneath.

Do you make foam inserts?

No, we do not make foam inserts. Many buyers search for custom foam inserts for boxes because foam is what they have seen before, but die-cut card, corrugated and molded pulp do the same job of holding a product in place. They also keep the whole package paper-based, which is easier for your customers to recycle. If your product is very fragile, tell us how it ships and we will suggest the strongest paper option.

How do I measure for a custom insert?

Measure each product and the inside of the box, then tell us how the items should sit.

1. Each product: length, width and height at the widest points, including caps, pumps or handles.
2. Layout: how many items go in one box and whether they stand up, lie flat or sit at an angle.
3. The box: its inside length, width and depth, or the product you want us to size a new box around.
4. Extras: a booklet, card or thank-you note that needs its own slot.

Our guide on how to measure a box explains inside and outside dimensions. For unusual shapes, a sample product lets us cut a test insert, and physical samples are ready in 5–7 days.

Printed packaging inserts and insert cards

An insert does not have to be plain. Printing your logo, a pattern or a product name next to each slot turns the insert into part of the brand experience. Some brands print short instructions or a QR code on the insert so customers know what to do first. A packaging insert can also mean a separate printed card, such as a thank-you note or care guide, and we can add a slot to hold it so it never falls out when the lid comes off.

Custom inserts for boxes by product

• Cosmetics and skincare: fitted cutouts for bottles, tubes and jars, often inside magnetic gift boxes.
• Candles: holders that stop jars and tins from shifting, as in our candle gift set boxes.
• Vials and samples: rows of small slots, with names printed next to each one, for vial boxes.
• Ecommerce kits: corrugated dividers inside mailer boxes keep products apart in transit.
• Premium gift sets: recessed card inserts in rigid boxes for a polished presentation.

Are custom box inserts eco-friendly?

Paper-based inserts are a simple way to cut plastic from your packaging. Card, corrugated and molded pulp inserts go into paper recycling with the box, and FSC-certified board is available on request. Plain kraft inserts work well for brands that want a natural look without extra coatings.

Ordering custom box inserts

Send your product sizes, the number of items per box and your box size, or ask us to design the box and insert together. We send a dieline and a digital proof, and production starts once you approve it. Inserts are made in 8–10 business days, or 10–12 for rigid gift sets. The minimum is 100 per design and size, and US orders over $500 ship free. You can see more ways to package retail products in our retail packaging range, or request a quote for custom inserts today.