Corrugated Packaging Inserts

What Are Corrugated Inserts—and Why Do You Need Them?

Corrugated inserts are custom-cut structures placed inside your packaging box to:

• Hold products securely in place
• Prevent breakage, scratching, or shifting during transit
• Organize multiple items neatly
• Enhance the unboxing experience with clean, professional presentation

Ideal for:

• Electronics and gadgets
• Fragile items like glassware or ceramics
• Subscription boxes with multiple SKUs
• Toolkits, cosmetics, and product bundles
• E-commerce shipping and retail kits

If your product moves, rattles, or breaks—corrugated inserts are your best defense.

Durable, Custom-Built Material

Corrugated board isn’t just strong—it’s smart. We use eco-friendly, high-performance corrugated cardboard that’s:

• Shock-absorbing and crush-resistant
• Lightweight for reduced shipping costs
• Recyclable, biodegradable, and FSC-certified (by request)
• Available in white, Kraft, or printed options
• Custom thickness (E-flute, B-flute, etc.) to match your product weight and fragility

Our inserts are engineered to fit your product like a glove—and your brand like a pro.

Precision Cut for a Perfect Fit

We offer a wide variety of insert styles to suit any application:

• Die-cut slots – For bottles, jars, candles, or tools
• Multi-cell partitions – For kits, collections, or sample boxes
• Layered inserts – For products with accessories or multiple parts
• Folding inserts – Flat-packed for space-saving, easy assembly
• Custom scored and glued inserts – Pre-built for fast packing lines

Each insert is designed using your exact product dimensions—no guesswork, no shifting, no damage.

Custom Printing for Instruction & Impact

Why not add some style or function to the inside of your box?

• Add branding, logos, or messaging to inserts
• Print instructions or diagrams for product placement
• Include care info, QR codes, or promotional content
• Match your insert color to your brand aesthetic

Corrugated doesn’t have to be plain—it can be powerful.

Designed for Efficiency and Scale

• ✔ Pre-cut and ready for fast packing
• ✔ Flat shipping to save space and storage
• ✔ Works with hand-packing or auto-assembly systems
• ✔ Compatible with any outer packaging: mailers, cartons, or rigid boxes
• ✔ Available in small runs or bulk production

Whether you’re sending 50 boxes or 50,000, we scale with your needs.

The 3P Advantage: Protection. Presentation. Performance.

Protection

Minimize damage, reduce returns, and deliver with confidence.

Presentation

A clean interior layout enhances the unboxing experience and reinforces brand quality.

Performance

Built tough to hold up during shipping, storage, and unpacking—time and again.

Why Brands Choose Custom Boxes Lab for Inserts

From indie brands to global manufacturers, we’ve helped thousands secure their products with custom inserts that work:

• No minimum order requirements
• Free structural design assistance
• Fast production and shipping
• Bulk pricing for high-volume runs
• U.S.-based support and global delivery

We make custom inserts easy—from idea to impact.

Get a Free Quote on Corrugated Packaging Inserts Today

📦 Make every shipment a secure success.
Order corrugated packaging inserts from Custom Boxes Lab and give your products the fit and protection they deserve.

When measuring a custom box, there are a few technical specifications that must be considered to ensure proper design, manufacturing, and fit for the product. Here are the major technical things to measure a custom box:

Inside Dimensions (Critical for Product Fit)

• Length (L): The longest side of the box measured inside from one corner to the opposite corner.
• Width (W): The shorter side of the box measured inside perpendicular to the length.
• Depth/Height (D or H): Measured inside from the bottom to the top opening of the box. Always specify that dimensions are given in Length × Width × Height.

Outside Dimensions (Important for Shipping & Storage)

• Measure the outer surfaces of the box including material thickness.
• Outside measurements are used for pallet stacking, warehouse spacing, and shipping compliance.

Material Thickness (Board Caliper)

• The thickness of the packaging material (e.g., corrugated board, rigid stock, cardstock).
• Impacts both the internal usable space and external dimensions.

Flap Measurements

• For boxes with flaps (e.g., mailer or shipping boxes), measure:
• Inner flaps: Ensure they meet in the middle without overlapping too much.
• Outer flaps: Allow proper sealing without gaps.

Tolerances

• Account for manufacturing tolerances (usually ±1/16" or ±2mm depending on material).
• Ensure the product fits without being too tight or loose.

Volume Capacity

• Calculate internal cubic capacity (L × W × H).
• Helps in determining how much space the product will occupy and shipping efficiency.

Product Orientation

• Decide how the product sits inside the box and measure accordingly.
• Orientation affects whether length or width is the primary dimension.

Die-Cut Openings or Windows

• Measure exact placement, height, and width for any cutouts.
• Ensure structural integrity when adding windows.

Printing Bleed & Safe Zones

• Include measurements for:
• Bleed area: Extra space beyond the cut line for printing.
• Safe zone: Inner area where critical text or logos should be placed.

Closure Type & Locking Tabs

• Measure slots, tabs, or locks for boxes with custom closures.
• Precision is required to avoid misalignment during assembly.

Packaging Style

• Folds, creases, and scores must be measured for accurate dieline creation.
• Different styles (e.g., RSC, tuck-end, mailer, sleeve) require specific panel measurements.