Custom Rigid Box with Inserts
Custom rigid boxes with inserts from 100 — a wrapped grayboard box and a cavity insert designed together, so every bottle, vial, device or set piece has its own place and stays in it from the packing table to the customer.
The cavity is cut first, and the box is built around it
- Board
- Wrapped grayboard rigid box, 1.5–2.5 mm; magnetic, lift-off or drawer closure
- Inserts
- EVA or PE foam, wrapped card, molded pulp, flocked tray
- Cavities
- Cut to measured products with allowance and finger notches
Order online
Order rigid box with inserts
Starting from $7.00 per unit
Printed to your artwork or plain, sold in runs of 100 up to 5,000 units per product online. Freight to the US, UK, Canada and Australia is inside the price.
How an online order runs
- Add the units you needThen check out with your delivery address. Add other products to the same order on the way.
- A digital proof comes backLaid on the dieline, before anything prints. Change it as often as you need.
- Pay once you approve itPay by PayPal invoice or bank transfer after you approve your digital proof, or cash on delivery in the US and Canada.
- We make it and ship it deliveredYour delivery date is confirmed with the proof, against the spec and your fill date. Freight and customs are handled on the way to you.
Another size, board or finish, or more than 5,000 units? Send the spec for a price instead. Freight by market and our terms cover delivery and remakes.
Get a price for Rigid Box with Inserts
Send the size and quantity — we reply the same working day with a price, a dieline and a date. Artwork optional at this stage.
- Free dielineThe flat drawing comes with the quote, before you commit.
- Proof before pressNothing is printed until you have seen it laid on the dieline.
- Die kept for reordersTooling is paid once. Every reorder skips straight to press.
- Quoted in four marketsUS, UK, Canada and Australia, in the delivery currency.
Three insert materials, chosen by the product
Foam holds best and is most forgiving of small size differences. Card looks most finished and recycles with the box. For a detailed look at foam grades, see our page on foam inserts for shaped cavities.
| Foam (EVA or PE) | Glass vials, devices, tools; cut cavities hold tight and absorb knocks |
|---|---|
| Wrapped card | Cosmetic sets, candles, tea; covered in the same paper as the box |
| Molded pulp | Bottles and jars where an all-paper box matters more than a crisp edge |
| Flocked tray | Jewelry and watches; a soft surface that does not scratch |
Measuring a product for a cavity
- Send the real product or its exact dimensions, including any cap, pump or label overlap.
- Note anything that varies between units, such as hand-poured glass or a tapered bottle.
- Say how the item comes out: lifted by a cap, pushed up from below, or pulled by a ribbon.
- Tell us the total weight, which sets the insert depth and the board under it.
A cavity sized to the product alone is too tight. We add a small allowance and a finger notch wherever an item would otherwise be hard to lift out.
Laying out a set so it reads on opening
In a box with five serums or a device and its charger, the layout is what the customer sees first. The hero item usually sits in the center or on the left, with smaller pieces arranged in a row so the eye moves across them. A printed card under the lid can name each item in the same order as the cavities, which saves a separate leaflet.
Closures for a box that is opened more than once
A magnetic flap keeps a set box closed on a dresser and opens with a fingertip. A lift-off lid suits a box that is opened once and kept as storage. A drawer suits a narrow set of vials. Whichever closure is used, the insert height is set so the lid presses lightly on the products and they cannot lift out of their cavities in transit.
Where these boxes end up
Skin care and fragrance sets, sample and discovery kits, vape and device kits, tasting sets, tool kits, launch boxes for press and influencers, and corporate gifts. For boxes where the lid is joined at the back, see our rigid boxes with hinged lids.
Rigid Box with Inserts — specification
The rows that are specific to this build first, then what applies to every job we run. Anything not listed is a question, not a limit — send the brief.
This build
- Board
- Wrapped grayboard rigid box, 1.5–2.5 mm; magnetic, lift-off or drawer closure
- Inserts
- EVA or PE foam, wrapped card, molded pulp, flocked tray
- Cavities
- Cut to measured products with allowance and finger notches
- Wrap
- Printed or specialty paper; soft-touch, foil, emboss
- Extras
- Printed card under the lid naming each item; ribbon pulls
- Minimum
- 100 boxes per layout
On every job
- Print process
- The wrap is printed offset as a flat sheet and applied to the board, so the print quality is that of a sheet rather than a box.
- Color
- CMYK on the wrap with spot colors for a brand match. A textured or soft-touch wrap mutes a solid color slightly.
- Tolerance
- Board cut plus or minus 0.5 mm. Lid fit is set on a sample and held on the run, with an allowance for the delivery climate.
- Tooling
- No cutting die on the box itself. The tooling is the wrap print and any foil or emboss die, made once and kept.
- Food contact
- A food-grade liner or an inner tray where a rigid box holds unwrapped food.
- Sustainability
- Board and paper recycle together. Magnets, ribbon and foam come out first, and the spec says which the box has.
- Artwork
- Vector PDF or AI, 3 mm bleed, 4 mm safe area, fonts outlined. We check every file and send a proof before press.
- Dieline
- Supplied free with the quote, before you commit. Yours whether or not you order.
- Sample
- A plain unprinted sample at the finished size on request, for fit and construction.
- Reorders
- Skip the tooling and go straight to press at a lower unit price.
- Lead time
- Quoted with the price against your fill date rather than promised before we have seen the spec.
- Markets
- United States, United Kingdom, Canada, Australia — priced in the delivery currency, freight included.
Boards and films we build rigid box with inserts on
A rigid box is two materials: the grayboard that holds the shape and the paper wrapped around it. The board decides the feel; the wrap decides everything a customer sees and touches.
Grayboard 1.2–1.5 mm
The light rigid box: jewelry, small cases, card boxes. Heavy in the hand for its size without thick walls on a small cavity.
1.2–1.5 mmGrayboard 2–3 mm
The full rigid box. Resists crushing, bends poorly — thickness is chosen from box size so a wide lid does not sag.
2–3 mmArt paper wrap
Printed coated paper, matte or gloss laminated. Full color, photographs, any design. The most flexible wrap and the least tactile.
128–157gsmSoft-touch wrap
A velvet-feel laminate over printed paper. Reads expensive, shows fingerprints on white, and scuffs at the corners before anywhere else.
128–157gsm laminatedLinen and textured wrap
Texture woven into the paper, so it cannot scuff off. Takes foil and deboss beautifully; breaks up a solid print.
120–140gsmLeather-grain and specialty
Embossed grain papers, metallics and colored stocks. One color and a foil mark, not a photograph.
120–160gsmFlocked and velvet liners
A short-fiber or woven pile for the interior and the insert. Holds a product without marking it and sets the color the piece is seen against.
Applied to board or foamMagnets and hardware
Neodymium magnets under the wrap, ribbon pulls, and hinges built from the wrap itself. Each is a line on the quote.
Per closureNot sure which? Say what goes in it and where it is sold — the material follows from that. Our notes on recycled, recyclable and compostable cover which claims each stock can honestly carry.
- 01
Send what you have
A dimension, a photograph beside a ruler, or the product itself. No technical drawing needed — that part is ours.
- 02
We quote and draw
A price, a dieline and a date come back together. If a different build would suit the product better, that is in the reply too.
- 03
Approve the dieline
The flat drawing is yours to check: which panel is the front, where the folds fall, how deep the cavity really is.
- 04
Artwork on the dieline
You place your design on the flat we sent, or we place it for you, and you see a proof before anything goes to press.
- 05
A sample if you want one
A plain unprinted sample at the finished size shows fit and construction — the things a drawing cannot.
- 06
Cut, printed, shipped
The die is cut once and kept, so every reorder skips the tooling and goes straight to press at a lower unit price.
Format
Vector PDF or AI where possible. Raster artwork at 300dpi at final size, in CMYK.
Bleed
3 mm past every trim line, so a fraction of drift on the cutter never leaves a white edge.
Safe area
Keep type and anything important 4 mm inside the cut and away from every fold.
Color
Convert to CMYK before sending. Uncoated stock prints lighter; a spot color is the only exact match.
Fonts
Outline them or supply the files. A missing font substitutes silently and the proof will not match.
Barcodes
On a light, matte, unvarnished patch with the quiet zone clear — a code on gloss fails the scanner.
Not set up that way? Send it anyway — fixing a file is a short conversation, and we check every one before press. Our guide to preparing print files covers each point.
On a rigid box the wrap is the finish, and the corners are where it is judged.
Soft-touch wrap
Velvet in the hand. The category default, and it scuffs at the corners first.
Linen and laid
Texture woven into the paper; hides marks and cannot rub off.
Hot foil
Stamped into the wrap. Small block, cheap die, large effect on a lid.
Blind deboss
Shape with no ink. On a textured wrap it is the quietest premium mark there is.
Spot UV on matte
A gloss shape on a matte field; a pattern that only shows at an angle.
Colored liner
A wrap on the inside face, seen for a second as the lid lifts. The cheapest thing that changes an opening.
Leather-grain
Embossed grain paper. One color and a foil mark, never a photograph.
Ribbon and hardware
A pull under the product, magnets under the wrap, a hinge built from the paper.
Not sure which suits the shelf it sells from? Say where the product is sold and we suggest one — our notes on specialty finishes show them on real boxes.
Sizing a rigid box, where the wrap is part of the wall: rigid box with inserts
A rigid box is built up rather than folded, so the internal size is set first and the board and wrap are added outside it. The lid is then made to fit the base, and that fit is the thing people judge.
- Internal dimensions
- The product plus its insert, at the widest point. Everything else is built outward from this number.
- Wall build-up
- Each wall is the grayboard plus the wrap on both faces — roughly 2.5 mm on a 2 mm board. A small box gains noticeably in outside size.
- Lid clearance
- A few tenths of a millimeter. Set on a plain sample: a slow, air-cushioned lift, not a lid that drops off or has to be prised.
- Insert depth
- The tallest item plus 2 mm. On a two-layer box, this sets the total height and the ribbon lift.
- Humidity
- Board takes up moisture and a lid set snug in a dry factory can bind in a damp shop. We allow for the delivery market.
- Tolerance
- Plus or minus 0.5 mm on a rigid box, tighter than folding board because nothing springs back.
Not sure your numbers are right? Send the product dimensions rather than the box dimensions and we work the box out — the full method is in our guide to measuring for a box.
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Build your Rigid Box with Inserts in 3D
Pick a shape, type a size, choose a board and a finish. The preview on the left redraws as you go, and the spec lands with us exactly as you set it.
Frequently asked questions
Got a question about rigid box with inserts? The answers below cover what we get asked most. If yours is not here, send it with a brief, message us on WhatsApp, or call +1 503-461-4788 — we reply the same working day.
What is a rigid box with inserts?
A wrapped grayboard box with a cavity insert inside it, designed together so each product has its own fitted place.
Which insert material is best for a rigid box?
Foam for glass and devices, wrapped card for cosmetic sets and a finished look, molded pulp for an all-paper build, flocked trays for jewelry.
What do you need to size the inserts in a rigid box?
The exact dimensions of every item, including caps and pumps, how each one is taken out, and the total weight.
Will a glass vial move inside a rigid box with inserts?
Not when the cavity is cut correctly. Foam holds a vial tight, and the lid is set to press lightly on top.
Can a rigid box with inserts hold different-sized products?
Yes. Each cavity is cut to its own item, so a bottle, a jar and a tube can sit side by side in one insert.
Can the inserts be covered to match the rigid box?
Yes. Wrapped card inserts use the same paper as the box, so the inside looks like part of the same design.
How do customers lift products out of a rigid box with inserts?
Through finger notches cut beside the cavity, a ribbon pull under the item, or a cap left standing above the insert.
Which closure suits a rigid box with inserts?
Magnetic flaps for sets that are opened often, lift-off lids for boxes kept as storage, drawers for narrow vial sets.
Can a rigid box with inserts include a printed card?
Yes. A card under the lid can name each item in the order of the cavities, which often replaces a separate leaflet.
Are rigid boxes with foam inserts recyclable?
The wrapped box is paper and board. Foam should be removed first; card or pulp inserts recycle with the box.
Can I see the insert layout before printing the rigid box?
Yes. The dieline sent with the quote shows the cavity layout, and a sample can be cut to test fit with your products.
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