Custom box inserts and packaging inserts
Custom Box Inserts
A custom insert holds the product in position so it does not move in transit and is presented properly when the box is opened. We make packaging inserts in card, corrugated board, wrapped greyboard and EVA or polyethylene foam, cut to your product's outline and sized with the box around it. Send your product dimensions and the number of items per box for a quotation.
- Materials
- Card, corrugated, greyboard, EVA or PE foam
- Fit
- Cut to your product's outline
- Used in
- Rigid, mailer, carton and corrugated boxes
- Minimum order
- 50 boxes
Overview
What an insert does
An insert has three jobs. It stops the product moving, so nothing scuffs, rattles or breaks. It separates items, so glass does not touch glass and small parts stay in place. And it presents the product at the right height and angle when the box opens, which is often what makes a box feel finished rather than merely filled.
The right material depends on the product. Foam inserts are cut to the product's outline and suit fragile or high-value items such as glass bottles, electronics, watches and jewellery. Card and greyboard inserts are printed or plain platforms, cradles and trays that suit cosmetics sets and multi-item packs. Corrugated inserts add structure and some cushioning inside mailer and transit boxes at low cost.
An insert is designed together with the box, not afterwards. The insert's size sets the box's internal dimensions, the cavity depth sets where the product sits, and the finger cut-outs decide how easily the customer lifts the product out. We draw both on the same dieline so they fit on the first run.
If a plastic-free box matters to your brand, card, corrugated and greyboard inserts keep the whole pack in paper-based materials, which is simpler for the customer to recycle than a box with a foam insert. Tell us at specification stage and we will design around it.
Structures
Boxes we build inserts for
Inserts are made for most box styles. These are the ones where an insert matters most.
Box style
Magnetic closure boxes
Foam or wrapped greyboard inserts that hold a product or set at a fixed height under the lid.
Read the style guideBox style
Lid and base boxes
Trays and cradles that present the product the moment the lid lifts off.
Read the style guideBox style
Drawer boxes
Shallow inserts that stop jewellery and small items sliding when the drawer opens.
Read the style guideBox style
Roll-end tuck front mailer boxes
Corrugated or card inserts that hold products still through a courier or postal network.
Read the style guideBox style
Crash-lock bottom cartons
Card cradles and neck holders that keep bottles and jars upright in the carton.
Read the style guideBox style
Corrugated lid and base boxes
Dividers and platforms for hampers, bottle sets and multi-item kits.
Read the style guide
Sizing
Sizing an insert
Send the dimensions of every item in millimetres, its weight and how many items sit in one box. For irregular shapes, such as bottles, devices or tools, a product sample or a detailed drawing gives the best fit, because cavities have to follow the real outline including caps, buttons and cables.
Tell us how the products should be arranged and which way up they sit. We allow a small clearance so products go in and come out without tearing the insert, and we add finger cut-outs or ribbon lifts where items are hard to grip.
The insert and box are sized together. Adding an insert to an existing box is possible, but designing both at once usually gives a smaller, neater box.
Materials & finishing
Insert materials compared
Each material has a different balance of protection, presentation and cost. Thicknesses are typical and vary by supplier; we confirm the material on your quotation.
| Specification | Typical range | Notes |
|---|---|---|
| Card inserts | Typically 300–400 GSM board | Folded cradles, platforms and dividers, plain or printed. Economical and paper-based; best for light, non-fragile products. |
| Corrugated inserts | E or B flute | Platforms, dividers and cut-out holders made from the same board as the box. Low cost, with more structure and some cushioning. |
| Wrapped greyboard inserts | Typically 1.5–3 mm board, paper-wrapped | Rigid trays covered in paper to match the box. A premium, paper-based alternative to foam for rigid boxes. |
| EVA foam | Dense, fine-cell foam | Cut to the product outline, often flocked or lined. Firm and precise, used for glass, electronics, watches and jewellery. |
| Polyethylene (PE) foam | Lighter, more cushioning | Softer foam for shock absorption in shipped products, often in layers with cut-outs. |
Finishes
- Printed card inserts
- Paper-wrapped greyboard to match the box
- Fabric or flocked lining over foam
- Ribbon lifts and finger cut-outs
- Foil-blocked logo on insert panels
Options
Options you can specify
Insert types
- Cradles and platforms
- Dividers and partitions
- Cut-out cavities
- Neck holders for bottles
- Layered trays for kits
Materials
- Card
- Corrugated board
- Wrapped greyboard
- EVA foam
- Polyethylene foam
Presentation
- Printed insert surfaces
- Matching wrap paper
- Ribbon lifts
- Finger cut-outs
- Lined cavities
Applications
Where custom inserts are used
Glass bottles and jars
Foam or card neck holders and cavities that stop glass touching glass and keep bottles upright.
Electronics
Foam or card cradles for the device with a separate compartment for cables, chargers and accessories.
Cosmetics and skincare sets
Printed card or wrapped greyboard trays holding several products in a fixed arrangement.
Jewellery and watches
Lined foam or card inserts with slots for rings, earrings and watch cushions.
Subscription and PR boxes
Corrugated or card inserts that present a month's items and stop them shifting in the post.
Candles
Card or corrugated inserts that hold the jar away from the box walls and keep the lid in place.
Food and drink gift sets
Dividers and platforms for jars, bottles and treats in hampers and gift boxes.
Compare
Foam insert or card insert?
| Feature | Foam insert (EVA or PE) | Card or greyboard insert |
|---|---|---|
| Protection | High; cushions and grips the product | Good for positioning; less cushioning |
| Fit | Cut to the exact outline | Cavities and folds shaped around the product |
| Look | Precise, often lined | Printed or wrapped to match the box |
| Materials in the pack | Adds a plastic foam | Keeps the pack paper-based |
| Best for | Glass, electronics, high-value items | Cosmetics sets, kits, light products |
How to choose
How to choose your insert
Start with fragility
Glass, electronics and high-value items usually justify foam or a well-designed greyboard tray. Robust products are well served by card or corrugated.
Think about the journey
An insert in a shipped box has to hold through drops and vibration. An insert in a gift box on a shelf mainly has to present. Tell us how the box travels.
Decide whether it should be seen
If the insert is visible when the box opens, print it or wrap it to match. If it sits underneath, a plain insert keeps the cost down.
Make it easy to lift out
Finger cut-outs, ribbon lifts and sensible cavity depths stop customers tipping the box to get the product out.
Consider plastic-free early
If you want an all-paper pack, choose card, corrugated or greyboard at specification stage so the box can be designed around it.
In detail
What makes an insert work
Accurate product measurements
Most insert problems come from measuring the product without its cap, pump or cable. Measure the finished product as it will be packed, or send a sample.
Cavity depth
The cavity depth sets how far the product sits below the lid. Too deep and the product looks lost; too shallow and the lid presses on it.
Consistency across a range
If several products share a box size, one outer can take different inserts. That keeps the outer box consistent while each product gets its own fit.
Finished work
Custom Inserts we have made
Foam, corrugated and board inserts 
Lid and base boxes Lid and base boxes Checking the fit of a foam insert
Custom Inserts questions
Questions buyers ask
Anything not covered here, put it in the notes on your quote and we will answer it directly.
Ask on your quoteWhat is a custom box insert?
It is the internal fitting inside a box, such as a card cradle, corrugated divider, wrapped greyboard tray or foam block, cut to hold a specific product in position.
Do I need an insert?
If the product can move inside the box, or if several items share one box, an insert is usually worth it. It prevents damage and makes the box look finished when opened.
Which insert material should I choose?
Foam for fragile or high-value items, wrapped greyboard for premium rigid boxes, card for light products and cosmetics sets, and corrugated for shipped boxes and heavier items. We recommend one once we know the product.
Can inserts be printed?
Yes. Card inserts can be printed, and greyboard inserts can be wrapped in printed or speciality paper to match the box.
Can you make a plastic-free insert?
Yes. Card, corrugated and wrapped greyboard inserts keep the whole pack paper-based. Tell us at specification stage so the box and insert are designed together.
Can you add an insert to a box I already have?
Usually, yes. Send the box's internal dimensions and the product, and we will design an insert to fit. Designing box and insert together often gives a better result.
What is the minimum order for custom inserts?
The minimum order is 50 boxes. Inserts are normally quoted with the box they go in, so include both on your quote request.
How long do inserts take?
Inserts are produced alongside the box, and foam cutting or greyboard wrapping adds steps. Tell us your required delivery date and our team will confirm whether the timing is achievable.
Ready to specify your packaging?
Our team replies during business hours, 10:00–18:00 UK time.