Custom box inserts can be a great way to transform your packaging and bring your unboxing experience to the next level. With the help of structural design engineers, custom box inserts are designed to cradle your products perfectly, adding a luxury factor to your packaging. You can look at them as the ultimate packaging accessory triple threat, allowing you to bring additional protection, communication opportunities, and aesthetic value to your products’ packaging.
When it comes to designing custom packaging inserts, there are several key considerations that need to be made. Custom inserts can be made with a variety of materials, each with their own unique set of characteristics. Accessing your product’s weight, fragility, and placement, as well as your packaging’s purpose and space requirements can help guide your design decisions including which materials you should utilize.
Paper Custom Box Inserts
Custom box inserts made using paperboard can often be seen for lightweight products. Due to their lightweight nature, they can allow for more cost-efficient packaging during shipping. Since they’re made out of paperboard, they are sustainable and also fully customizable allowing you to add any branding designs or educational information to them.
They can be a great option for those looking to add some style to the interior of their packaging through additional designs or by strategically placing their products. They can also be great for nicely showcasing and organizing your products within the packaging to avoid any smaller objects getting lost within.
Plastic Custom Box Inserts
Alternatively, plastic can also be used to make custom box inserts. Made from plastic, they can be an economical choice. Due to the nature of plastic, they will be able to be molded precisely to your product. However, since they are made with plastic, that also means that they are less sustainable than paper custom box inserts.
Corrugated Custom Box Inserts
Corrugated custom box inserts are made using fluted materials allowing them to provide additional protection. The fluted cardboard can absorb more unexpected forces and impact during transport, making corrugated custom box inserts a great choice for shipping heavier or fragile items while still maintaining the ability to fully customize them and add designs. Made fully from cardboard, they are easy to recycle, making them a highly sustainable choice.
Pulp Custom Box Inserts
Pulp custom box inserts are often made using recycled post-consumer content and can be molded to fit your products like a glove. They are suitable for those looking for a sustainable packaging option that has a precise fit. However, since pulp inserts require a mold to allow for this exact fit, the cost for pulp custom box inserts can be considerably higher compared to other types of custom inserts.
Foam Custom Box Inserts
For those willing to sacrifice customizability for additional protection, foam custom box inserts are a great choice. Made from foam materials such as PU foam and EVA foam, they allow for even more cushioning than paper-based box inserts. PU foam is an airier and malleable material that resembles a sponge whereas EVA foam is quite firm and dense similar to a yoga mat. Made from plastic foam, they are a less sustainable option compared to paper-based custom box inserts.
Often available in white or black, foam box inserts are lightweight and help to secure products by minimizing vibrations. Though they lose some of their customizability as they can’t be printed on, some brands have been seen to get creative by adding a layer of cloth or silk on top to create a luxurious feel.
Custom Box Dividers
For those looking to organize their products within the packaging and do not feel the need to undergo structural engineering to get precise custom box inserts, custom box dividers are a great alternative. With the ability to be made from paper or corrugated materials, they are a simple way to add a little bit of organization to ensure that your products aren’t jostling around during transport. They can be a more time-efficient process to obtain as they will not have to be designed around your product and are more versatile as they can be used across various product lines.