Custom Die-Cut Inserts
Our custom-designed inserts give your inventory the protection it needs. These die-cut solutions stop items from shifting in the box, so even fragile glass vials or heavy parts stay secure from the warehouse all the way to your customer.
| Specification | Details |
|---|---|
| Material Options | Corrugated (B/E/F Flute), SBS Paperboard, Kraft |
| Sustainability | 100% Recyclable, Post-Consumer Waste (PCW) |
| Finish Types | Matte, Gloss, Soft-touch, Uncoated |
| Max Sheet Size | 28" x 40" |
| Tolerances | +/- 1/32" |
| Customization | Full-color CMYK or PMS Spot Printing |
Rigid Inserts That Offer Strong Impact Protection
Standard one-size-fits-all packaging often leaves gaps, which can cause friction and damage. When we design our inserts, we pay close attention to the thickness of the paperboard and the strength of the folds. Unlike packing peanuts that shift or air pillows that can pop, a rigid die-cut insert keeps your item securely in place. So, even if the box is dropped, the outer walls and the insert absorb the impact, not your product.
High-Precision Inserts for a Lasting First Impression
When a customer opens your package, the way everything is arranged shapes how they see your brand. A messy box can make your product seem less valuable, while a neat, organized layout shows quality and care. We use precise steel-rule dies to make sure every edge is clean and professional.
If you want to add extra information or a personal touch, you can include booklets or thank you notes in special slots. This way, customers get a thoughtful unboxing experience that guides them through your product step by step.
Precision Fit for Every Product and Payload
No matter if you ship luxury skin care or industrial parts, getting the right fit is key. For heavier electronics, using these structures with foam inserts helps reduce vibration. For lighter, high-volume retail products, recycled paperboard inserts are a cost-effective and sustainable choice that still keeps your packaging strong.
Friction-Fit Geometry for Tool-Free Assembly
We design our inserts to help your team work faster. With easy-to-follow fold lines and locking tabs that snap together, there’s no need for glue or tape. This makes packing quicker and helps lower your labor costs.
Plastic-Free Inserts for Guilt-Free Recycling
Today’s customers want packaging without plastic. Our paper-based die-cuts create a single-material solution, so the whole box and its inserts can go straight into a regular recycling bin. This removes the guilt that comes with plastic or styrofoam packaging.
Frequently Asked Questions About Custom Die-Cut Packaging
We’ve answered the most common questions from our customers to help you choose the best options for your next production run.
Read our Custom Packaging Support & Ordering FAQs →What information do I need to provide for a custom-fit insert?
To make sure your insert fits perfectly, we need your product’s physical dimensions (Length x Width x Height), or even better, a sample. These details help us allow just enough space so your item is easy to remove but stays secure.
Is there a one-time tooling cost for die-cutting?
Yes, custom shapes need a steel-rule die, which is a one-time upfront cost. This tool lets us cut with great precision and speed. For larger or ongoing projects, your cost per unit goes down, making this a cost-effective way to get a professional result.
Can these inserts hold multiple items of different weights?
Yes, we can do that. We design inserts with multiple spaces, and we can adjust how tightly each item fits. For example, we can make a snug spot for a heavy glass bottle and a looser one for a light instruction sheet.
How do these compare to standard partitions or dividers?
Cell dividers work well for separating identical items like jars or bottles. But if your items have unique shapes, die-cut inserts are a better choice. Die-cutting lets us create 3D shapes that regular straight dividers can’t match.
What is the typical lead time for a custom prototype?
After we get your product’s measurements, we usually make a plain sample (an unprinted CAD prototype) in 3-5 business days. You can use this to check the fit and test the packaging before we start full production.
Do I need glue to assemble these inserts?
Most of our inserts are designed to ship flat and can be put together by hand in seconds, with no glue needed. This helps you save on shipping costs and keeps your workspace tidy.
