Jun 21, 2026Home Routines
How to Design a Custom Packaging Insert
📏 Measure Your Product
Start by measuring every product that will sit inside the box. Include caps, labels, pumps, lids, wrappers, and any product variation. If the product is fragile, identify the areas that need the most support.
🎯 Define Insert Purpose
Next, define the purpose of the insert. Is it mainly for shipping protection, retail display, premium unboxing, product organization, sustainability, or all of these? A shipping-focused insert may need stronger cushioning, while a gift-set insert may need better visual balance.
♻️ Select Material
Then choose the right material. For lightweight retail products, paperboard may be enough. For heavier ecommerce shipments, corrugated or molded pulp may be safer. For fragile high-value items, foam or specialty inserts may be needed.
✅ Test the Fit
Finally, test the fit. A custom insert should hold the product securely without making it hard to remove. If customers struggle to take the product out, the insert may be too tight. If products move when the box is shaken, the insert may need adjustment.
