Custom Styrofoam Packaging

Lightweight, Tough, and Tailored to Fit

Styrofoam isn’t just padding—it’s an engineering solution. With our custom packaging, you can protect your products without adding weight or bulk, making shipping safer and more cost-efficient.

Materials

We offer different grades of foam to suit your packaging needs:

• EPS (Expanded Polystyrene) – Ideal for thermal insulation and shock absorption
• EPE (Expanded Polyethylene) – Soft and flexible for delicate products
• PU Foam – Best for intricate protection and cushioning
• Eco-alternatives – Available upon request for more sustainable options

Sizes

Made to fit your product, every time:

• Custom-cut inserts for electronics, glassware, or tools
• Molded forms for medical kits or temperature-sensitive items
• Bulkier packaging for large appliances or machinery
• Compact designs for small, fragile items like vials or sensors

Printing

Even foam packaging can reflect your brand:

• Branding on outer cartons that house Styrofoam inserts
• Custom tags, sleeves, or stickers for added brand touch
• QR codes on boxes for tracking or product info

Add-ons

Make your packaging complete with practical upgrades:

• Outer corrugated boxes with foam lining
• Temperature-controlled Styrofoam boxes for perishables
• Custom dividers, lids, or layered protection
• Seals, handles, or wrap-around packaging options

The 3Ps Approach

Presentation

We make sure even technical packaging like Styrofoam looks clean, functional, and professional—matching the quality of what’s inside.

Preservation

Our Styrofoam protects contents from vibration, temperature swings, and impact, preserving product integrity from warehouse to destination.

Protection

Styrofoam’s shock-absorbing and thermal properties make it the go-to choice for packaging that must arrive intact, no matter the conditions.

Why Choose Custom Boxes Lab?

Businesses in healthcare, electronics, food, and industrial sectors trust us for protective packaging that meets industry standards:

• Custom molds designed from scratch
• Quick prototyping and design consultation
• Bulk orders and low MOQs available
• Eco-friendly alternatives and recycling advice
• U.S.-wide delivery with fast turnaround times

Get a Quote Today

Keep your fragile and valuable products safe the smart way. Call 0000 or email us to start your custom Styrofoam packaging project with Custom Boxes Lab.

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.