Precision die-cut EVA foam, molded pulp, and corrugated paperboard inserts engineered to lock your products securely in place and prevent transit damage.
Choose from our highly tailored structural variations built specifically to balance aesthetics with maximum product protection.
"Our glass dropper bottles used to smash constantly during transit. Pak CustomBox engineered an interlocking corrugated insert that acts like a shock-absorber. Zero breakages since."
Tell us about your box dimensions and quantity to get a custom factory estimate.
Request our free material sample kit to see actual printed textures, foil stamping, and structural folds before committing to a production run.
The exterior of a box sells the product; the interior insert ensures it survives the journey. Simply throwing products into a box with loose crinkle paper or bubble wrap looks unprofessional and offers minimal protection against heavy courier drop impacts. Pak CustomBox specializes in engineering custom interior cavities that map perfectly to the exact physical contours of your products, suspending them safely away from the outer crush zones of the master carton.
For eco-conscious brands and high-volume e-commerce shipping, paper-based inserts are the optimal choice. Using E-flute corrugated board or 24pt SBS paperboard, we engineer complex folded architectures, including platform trays, multi-cell partition grids, and suspension bridges. These structures provide immense shock absorption for heavy glass jars or multi-item kits, and because they are made of 100% paper, the end consumer can toss the entire box into their curbside recycling bin without separating materials.
For high-value luxury goods—such as electronics, fragile cosmetics, or expensive tooling—we utilize precision die-cut High-Density Ethylene-Vinyl Acetate (EVA) foam or softer Polyurethane (PU) sponge. Foam provides absolute rigid immobilization. We use CNC routing and die-punching to cut exact negative-space cavities matching your product. To elevate the presentation, the foam can be topped with a printed cardstock layer, or 'flocked' with a soft, luxurious velvet layer in colors like deep black or royal crimson.
When producing tens of thousands of units, custom molded pulp (similar to traditional egg-carton material but highly refined) offers an incredibly protective, 100% biodegradable insert solution. We create custom aluminum factory molds that press wet recycled paper fibers into exact 3D shapes, providing a premium, sustainable unboxing experience for tech hardware and heavy glass cosmetics.
Die-cut corrugated paperboard inserts and custom molded pulp trays are the most sustainable options, as they are 100% recyclable, biodegradable, and made from post-consumer waste.
You simply ship us a physical sample of your product, or provide a precise 3D CAD file (.STEP or .OBJ). Our engineers will map the exact contours and add proper finger-notches for easy removal.
Yes! If you choose a folded paperboard or corrugated insert, we can print full-color graphics, assembly instructions, or hidden marketing messages directly onto the insert surface.
EVA foam is highly dense, rigid, and feels like hard rubber, making it perfect for heavy tools or luxury presentations. Standard PU sponge is soft and squishy, ideal for lightweight, highly fragile items.
