Packaging Structure Design Corrugated Inner Support Product Custom Printing
Product Video
We have created a video tutorial on how to assemble double plug and airplane boxes. By watching this video, you will learn the proper assembly techniques for these two types of boxes, ensuring that your products are perfectly packaged and protected.
Common Insert Structures
With custom box inserts, there's no 'one size fits all'. The size, weight, and position of products all affect how the insert needs to be structured to secure each product. For reference, here are some examples of common insert structures.
Box Insert (No Backing)
Most commonly used for products that can sit directly at the base of the box and don't need to be elevated. These types of inserts are also ideal for products of the same size.
Box Insert (With Backing)
Most commonly used for products of the same/similar size that need to be elevated in order to fit securely in the insert. Otherwise, the products will fall through.
Box Insert (Multiple Backings)
Most commonly used for products of different sizes that need to be elevated in order to fit securely in the insert. Each backing is tailored to the size of the product and ensure they don't fall through the insert.
Sturdy and secure
Custom box inserts are tailored to the precise size of your products, keeping them secure in transit while giving your customers a truly elevated unboxing experience.
Structurally Engineered to Perfection
Creating the optimal insert design requires more than meets the eye. Products come in various shapes, sizes, and weights, which means using the right materials, creating structures to securely hold each product, and ensuring the insert fits precisely with the outer box.
Most brands don't have a structural design team, which is where we can help! Start a structural design project with us and we'll help you bring your packaging vision to life.
Technical Specs: Custom Box Inserts
E-flute
Most commonly used option and has a flute thickness of 1.2-2mm.
B-flute
Ideal for large boxes and heavy items, with a flute thickness of 2.5-3mm.
Designs are printed on these base materials which is then glued to the corrugated board. All materials contain at least 50% post-consumer content (recycled waste).
White Paper
Clay Coated News Back (CCNB) paper that's most ideal for printed corrugated solutions.
Brown Kraft Paper
Unbleached brown paper that is ideal for only black or white print.
White Paper
Solid Bleached Sulfate (SBS) paper that yields high quality print.
Brown Kraft Paper
Unbleached brown paper that is ideal for only black or white print.
Box inserts can also be made of foam, which are best for fragile items such as jewelry, glass or electronics. However, foam inserts are the least eco-friendly and cannot be printed on.
PE Foam
Polyethylene foam resembles a sponge-like material. Available in black or white.
EVA Foam
Ethylene Vinyl Acetate foam resembles a yoga mat material. Available in black or white.
CMYK
CMYK is the most popular and cost effective color system used in print.
Pantone
For accurate brand colors to be printed and is more expensive than CMYK.
Varnish
An eco-friendly water-based coating but doesn't protect as well as lamination.
Lamination
A plastic coated layer that protects your designs from cracks and tears, but not eco-friendly.
Matte
Smooth and non-reflective, overall softer look.
Glossy
Shiny and reflective, more prone to fingerprints.
The Order Process for Custom Box Inserts
A 7 step process to designing and ordering custom box inserts.
Structural design
Start a structural design project with us to receive an insert and box design that's been tested to fit your products.
Purchase a sample (optional)
Get a sample of your mailer box to test size and quality before starting a bulk order.
Get a quote
Go to the platform and customize your mailer boxes to get a quote.
Place your order
Choose your preferred shipping method and place your order on our platform.
Upload artwork
Add your artwork to the dieline template we'll create for you upon placing your order.
Start production
Once your artwork is approved, we'll start production, which typically takes 12-16 days.
Ship packaging
fter passing quality assurance, we'll ship your packaging to your specified location(s).
