Give each item a firm place in its box. Get custom foam inserts for retail goods, kits, tools, electronics, glass items, candles, and high-end gifts. Each insert fits the item’s size, shape, weight, and display plan. Customize them according to your packaging and product needs.
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Custom Boxes Tech makes wholesale custom foam inserts for retail and shipping boxes. Our team matches the foam, cavity, box, and finish to your sales plan.
Brands across the USA, UK, and Canada can order customized inserts with measured product cavities. Share the size, weight, quantity, photos, and box style for a Precision-Fit plan.
Send your product size, quantity, foam choice, and your custom packaging box style for a measured quote.
Foam choice affects grip, surface care, and shock absorption. Soft PU foam suits light gifts. Firm PE foam supports tools. Dense EVA foam gives display packs a Premium look.
Foam type | Cell style | Common density range | Best use |
PU | Open-cell foam | 1.2–2.2 lb/ft³ | Glassware, camera parts, and light gifts |
PE/EPE | Closed-cell foam | 1.2–4.0 lb/ft³ | Tools, parts, and devices |
EVA | Dense closed-cell | 2.0–8.0 lb/ft³ | Jewelry, cosmetics, and display sets |
Our custom cut foam inserts for fragile product sets can hold one item or more than 20 parts. Separate slots also help packers spot a missing piece.
A foam insert for boxes with firm edge support can guard heavy parts. We adjust the foam density to suit the product and shipping route.
Custom Boxes Tech offers volume rates for launches and repeat orders. These USA planning prices use USD. Size, material, cut depth, quantity, and freight affect the quote.
Insert option | 100 units | 500 units | 1,000+ units |
Soft PU, 1–2 cavities | $2.25–$5.50 | $1.20–$3.25 | $0.75–$2.10 |
Firm PE/EPE | $2.75–$6.50 | $1.50–$4.00 | $0.95–$2.75 |
Dense EVA | $3.25–$8.50 | $1.85–$5.00 | $1.20–$3.75 |
Two-color layered foam | $4.00–$10.00 | $2.40–$6.50 | $1.55–$4.75 |
Anti-static foam | $4.50–$12.00 | $2.75–$8.00 | $1.75–$6.00 |
Our custom foam box inserts for low-volume product launches start at 100 pieces. Orders of 1,000 units may cut the unit price by about 20%–55%, based on the size and build.
CBT plans the cavity around the real item. Send a CAD file, sample, or exact L × W × H details.
Foam thickness: 0.25–4 inches or 6–102 mm
Cavity allowance: 1/32–1/8 inch
Finger notches: 0.5–1.25 inches wide
Layers: 1–4 per insert
Product reveal: 25%, 50%, or 75% based on display needs
Common colors: Black, white, charcoal, blue, and red
Custom sizing: 100% based on the approved product data
Our box foam inserts with deep bottle slots can support tall jars, tools, and device parts. A strong base layer helps keep the product above the box floor.
Our team selects the cut method by shape, volume, depth, and edge detail. Precision cutting helps each slot follow the approved layout.
Cut method | Best use | Main benefit |
Steel-rule die | Flat shapes and repeat runs | Fast output at higher volumes |
Laser cut | Detailed top layers and fine shapes | Sharp edges and neat lines |
Layer bonding | Deep wells and two-color layouts | Strong depth and easy item control |
A custom foam insert with layered tool pockets keeps each tool in a fixed place. A bright lower layer also makes an empty slot easy to see.
Our team can match the insert with folding cartons, mailers, or rigid gift boxes. One plan aligns the logo, cavity, and product face.
Matte lamination for a soft, low-glare face
Gloss lamination for bright color
Soft-touch coating for a smooth feel
Foil stamping for logos and short text
Embossing or debossing for raised or pressed marks
Velvet lining for jewelry and gift packs
Brands can add custom packaging accessories for luxury product sets, such as ribbon pulls, sleeves, paper bands, and product cards.
The table helps buyers plan a basic budget. The rates cover one insert and standard cavities. Extra layers, special colors, and surface lining can raise the price.
Common size | Suggested use | 100 units | 1,000+ units |
4 × 4 × 1 in | Jewelry or small parts | $2.00–$4.50 | $0.65–$1.80 |
8 × 6 × 2 in | Beauty or device kit | $3.25–$7.50 | $1.10–$3.10 |
12 × 10 × 3 in | Tool or sample set | $5.50–$12.50 | $2.25–$6.25 |
18 × 12 × 3 in | Field or sales kit | $8.50–$19.00 | $3.75–$9.50 |
A custom foam packaging insert for an eight-piece device kit can separate the unit, cable, plug, manual, and spare parts for a Secure reveal.
Buyers can order an insert alone or with a printed box. UK and Canadian quotes reflect freight, duties, and currency rates.
Full packaging option | 100 sets | 500 sets | 1,000+ sets |
Folding carton plus foam | $4.00–$12.00 | $2.25–$7.50 | $1.45–$5.25 |
Corrugated mailer plus foam | $5.50–$15.00 | $3.25–$9.00 | $2.10–$6.50 |
Two-piece rigid box plus foam | $8.00–$22.00 | $5.00–$15.00 | $3.75–$11.00 |
Magnetic rigid box plus foam | $10.00–$28.00 | $6.50–$18.00 | $4.75–$13.50 |
Our custom packaging foam inserts for branded mailer kits center the item and create a High-Impact display.
A Custom Box Divider Insert for multi-item kits can cost less when the goods need more than deep cushioning. Foam pads can guard only the main contact points.
For glass jar sets, Candle Boxes with Inserts for wholesale gift packs keep each jar apart. Brands should test the full pack against its real weight and shipping route.
CBT reviews the item, insert, and outer box together. Our quote lists each cost and fit detail.
Product size and weight
Box length, width, and depth
Foam type, color, and thickness
Number of cavities
Cavity depth and product reveal
Cut style and layer count
Print, finish, and lining
Quantity and delivery market
Our custom foam inserts for boxes with repeat-order layouts help brands keep a steady pack style. Report each product change before reordering.
Custom Boxes Tech has served packaging buyers since 2002. Our quality team checks seven points against the approved design.
Material type
Foam thickness
Overall size
Cavity position
Cut edges
Layer bond
Fit inside the outer box
A foam insert for boxes with narrow walls needs enough space between cavities. Our team flags weak gaps before production starts.
CBT provides free design help, sample support, 24/7 customer care, quality checks, and after-sales service. We can help with repeat quantities, size changes, and new product layouts.
Our custom foam box inserts for USA, UK, and Canadian brands give buyers a Cost-Smart route from a 100-unit test order to a larger run.
Task our technical team at 1 (888) 247-7075 to configure ESD-safe custom foam inserts for the supply chain.
Rigid Cardboard
Premium White Cardboard
White Kraft
SBS C2S
Texture Paper
Metallic Paper
Natural Brown Craft
Holigraphic Paper
Black Kraft
Adhesive Paper
Adhesive Vinyl
Digital Printing
Offset Printing
UV Printing
Silk Screen Printing
Flouroscent Color Inks
Water Based Inks
Pantone Metallic
Soy/Vegetable Based Inks
Oil Based Inks
Pantone Colors
Gloss UV
Lamination
Anti-Scratch Lamination
Aqueous Coating
Silk Lamination Cards
Soft Touch Coating
Drip-off / Sang-glass
Embossing
Debossing
Holographic Foiling
Window Patching
Hotfoil Stamping
Coldfoil Printing
place an order through our secure payment process
flat and 3D view proofs of final product
approval or any revisions if required
prodcution starts right after your final approval
order will be delivered at your doorstep
We create custom packaging that combines premium presentation, smooth ordering process with reliable and dependable delivery for brands that value quality and efficiency.
Packaging Experience Since 2002
Serving the packaging industry since 2002
In-House Manufacturing
Production facilities in USA & Asia
Low Minimum & Flexible Customization
Starting from as low as your numbers
Global Service with Fast Turnaround
07-12 Bussiness days all accross the globe
Quick answers to help you get started with confidence.
We manufacture high-density polyethylene foams engineered for industrial applications to support extreme weight thresholds safely:
Under 50 lbs: A 1.7 lb density foam provides shock-absorbing cushioning for light instruments.
50 to 150 lbs: Our 2.2 lb density foam offers heavy-duty structural support for automotive parts.
Over 150 lbs: We use 4.0 lb cross-linked foam to deliver uncompromising rigidity for massive industrial pumps.
Over 500 lbs: Custom Boxes Tech builds multi-layered high-density blocks that withstand crushing forces.
