Vial Box With Inserts

More Than a Box—It’s Custom Protection in Every Slot

From eCommerce delivery to retail display, our vial boxes with inserts protect your product and promote your identity.

Materials That Support & Safeguard

We use high-strength materials that combine structural integrity with shelf appeal.

• Rigid chipboard, kraft, or SBS paperboard exterior
• Foam, EVA, cardboard, or molded pulp inserts
• Matte, gloss, or soft-touch finishes
• Eco-conscious and recyclable options available

Custom Inserts That Fit Like a Glove

Every vial gets its own place—snug, secure, and perfectly sized.

• Foam cutouts (white or black) with precision die-cuts
• Cardboard grid inserts for shipping-friendly flexibility
• Velvet-wrapped or silk-lined inserts for luxury presentation
• Multi-tier inserts for kits with multiple vial sizes or accessories

Tailored Sizing & Box Styles to Match Your Brand

We customize every detail so your box fits your products and your aesthetic.

• Single-vial, 2-pack, 4-pack, 6-pack, 10-pack, or custom configurations
• Magnetic-closure, tuck-end, drawer-style, or flip-top formats
• Add compartments for droppers, instructions, or labels
• Compact shipping boxes or upscale gift boxes available

Printing That Reflects Premium Care

Your product may be small, but your branding makes a big impact.

• Full-color CMYK or Pantone-matched artwork
• Foil stamping, embossing, or spot UV for elegance
• Inside/outside printing for a complete brand story
• Add barcodes, usage instructions, or QR codes linking to videos or tests

The 3Ps Approach

Presentation

Elegant packaging design that instantly communicates quality and care—perfect for retail, gifting, or sampling.

Preservation

Custom inserts reduce shifting, breakage, and exposure—ensuring your vials arrive intact and ready to use.

Protection

Durable exterior with secure interior support built to withstand transit, storage, and handling.

Why 5,000+ Brands Trust Custom Boxes Lab for Vial Packaging

Because we know how to combine safety with sophistication.

• Low MOQs—ideal for launch kits, samples, or short-run production
• Free dieline setup and custom layout support
• Fast U.S. production and shipping
• Medical-grade and cosmetic-compliant materials available
• A creative team that understands function, form, and compliance

Let’s Package Your Vials with Confidence and Class

Whether you’re shipping a serum, a sample, or a scientific solution—we’ll help you create custom vial boxes with inserts that protect and impress. Call us at 0000 or email today to get started 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.