Designers often choose inserts late in the packaging process.
That is where problems start. The insert controls how a product sits, moves, and appears. A weak choice affects protection, cost, and client satisfaction.
This guide explains the main types of custom inserts used in rigid boxes. It focuses on how designers actually think when selecting one for a client’s product.
You want to make a custom box to enhance the product’s presentation. But making it to complement the nature of the packaged product is a whole other new challenge.
One way to enhance the product’s protection & presentation is to offer inserts as an add-on option.
So the premise of this blog is to help you understand:
Let’s explore this topic further so you can select a promising type of insert for your client’s product or perhaps yours.
Most brands pick inserts based on what looks good.
But if the insert doesn’t match the product’s needs, things go wrong.
Your item shifts during shipping.
Or it arrives damaged.
Or the box feels cheap when opened.
The fix?
Match the insert to what matters most—protection, presentation, or purpose.
Below are common insert types and when to use them.
| Insert Category | Material | Main Job | Best For | Trade-Off |
| Position-Control Inserts | Cardboard trays | Hold in place | Cosmetics, accessories | Won’t cushion drops |
| Shock-Absorbing Inserts | Foam or rubber | Protect from impact | Electronics, glass | Costs more |
| Presentation Inserts | Fabric or wood | Premium unboxing | Jewelry, luxury gifts | Takes up space |
| Sustainability Inserts | Molded pulp | Reduce waste | Eco-conscious brands | Limited shapes |
| Multi-Item Inserts | Dividers or trays | Separate products | Kits and sets | Little padding |
| Problem-Specific Inserts | Magnetic or snap-fit | Custom solutions | Reusable packaging | Needs exact design |
Customer products come in different shapes, styles, and sizes. Different products require different levels of support, presentation, and environmental consideration. And so do we have different insert options.
PE foam provides reliable shock absorption and is widely used for protective packaging.
PU foam is softer and more comfortable than PE foam, making it a common choice for consumer electronics and accessories.
EVA foam offers a smooth, dense surface with high durability under repeated use. It looks and feels more refined than standard PE or PU foam.
Paperboard inserts are lightweight and structured. They are the most cost-effective option and work well for products that do not require impact absorption.
Molded pulp inserts are formed from recycled paper fiber — typically newsprint, cardboard, or sugarcane bagasse — and are compostable or recyclable depending on the binder used.
Plastic trays — typically formed from PET, PVC, or PETG — offer clear product visibility and rigid, structured placement.
Fabric-lined inserts — typically foam or board cores wrapped in velvet, suede, satin, or microfiber — add softness and a distinctly luxurious feel.
From Premier Rigid Boxes, picking the right insert means thinking about several things at once.
Heavy products require strong, dense inserts to prevent movement. Fragile items like glass, ceramics, or delicate instruments need soft, shock-absorbing foam rather than hard paperboard or plastic trays, which can transfer bumps rather than protect the product.
An insert that holds a product on a shelf might not protect it in a box dropped from a few feet. If your products are delivered through a network, make sure the insert is tested for shipping. Standards such as ISTA 2A and ASTM D4169 are common test methods. Ask your packaging supplier if they do this testing or can help with it.
Luxury brands often choose EVA foam, fabric-covered inserts, or premium molded pulp for a high-end feel and look. Mid-market brands might mix paperboard with foam. The insert should match the price and story of the box outside.
If your brand promotes eco-friendliness, choose inserts that align with that promise. Molded pulp and plain paperboard are strong choices. Be careful claiming recyclability for coated paperboard or standard plastic trays—check with your supplier first.
Your budget affects both the cost per unit and the minimum order quantity. Paperboard and standard foam usually have the lowest minimums and need little or no special setup. Custom foam shapes, molded pulp, or fabric-covered inserts cost more upfront and usually require at least 500–2,000 units. Talk about this early with your supplier.
Inserts can show brand colors, logos, or printed tissue paper. Paperboard and molded pulp are the easiest to print on. Fabric-covered inserts give a nice feel but limited print options. EVA and PU foam can be embossed or wrapped. If showing your brand on the insert is important, plan for it when picking the material.
So that’s the end of this blog. Hopefully, you have learned the stuff we promised earlier. Let’s recap the types of custom inserts we learned.
Let’s make sure what we do brings value to people who trust us to do a fine job.
Cathy
