Custom inserts

A custom insert does two things at once: it keeps the product still and decides the order in which the unboxing happens. Both come down to millimetres.

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Custom insert with cut cavities holding a product in place

From product to insert

We measure the product in three directions, define which surfaces may carry weight and then add tolerance for material and production variation. A physical insert is then tested before tooling or dies are ordered. Without a sample, an insert easily ends up either binding or letting the product move.

Material and feel

Board: crisp edges, printable, easy to recycle.
Moulded pulp: soft shapes and good cushioning, requires tooling.
Foam: precise routed cavities for heavy or fragile products.
Fabric-covered inserts for a premium feel in jewellery and accessories.

The order of unboxing

The insert controls what the customer sees first. A card or cloth over the product creates a pause; a cavity with a finger notch means the product is lifted out with two hands rather than shaken out. Details like these usually cost little but are clearly noticed.

Volume and tooling

Board inserts work from around 250-300 units.
Moulds for pulp and foam need higher volumes to pay off.
Lead time normally 6-8 weeks after confirmed design.

Close-up of the insert cut edge and the tolerance around the product

Material, structure and finish in detail

We review board quality, thickness, fit, print technique and finishing with you and turn it into a specification a supplier can produce against.

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FAQ

Frequently asked questions

Can one insert fit several product variants?: Often yes if dimensions are close. The alternative is one outer box with different inserts, giving a better fit per variant.
How do I avoid scratching the product?: Through soft surface material at contact points and enough tolerance that the product does not rub the edges.
Do I need a physical sample?: We strongly recommend it for inserts. Samples start from approx. SEK 1,500 and often save an entire production run.
Can the insert change later without a new box?: Yes, if the outer box internal dimensions stay unchanged. That is one advantage of keeping the box neutral.

Inserts and void fillDamage happens when the product moves. An insert that holds the product in place is nearly always more effective, and cheaper over time, than adding more void fill.Read more Premium boxesRigid board wrapped in printed paper gives the heavy, precise feel associated with premium. We build the box around your product and specify material, finish and inserts before production starts.Read more Premium jewellery packagingJewellery packaging is small, handled often and judged close up. Fit, surface feel and how the insert holds the piece matter more than size or print area.Read more Structural design & product developmentEngineering is where an idea becomes manufacturable. Dimensions, creases, locks and tolerances are decided here, and mistakes are found cheaply rather than expensively.Read more

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