Made to your size- 100 boxes
- Custom sizes & styles
- Free dieline support
- Quality print options
- Proof before production
- 8–12 business day production
Rigid boxes with inserts pair a rigid lift-off or magnetic box with an insert cut to the product - foam, cardboard, or wrapped rigid board. The insert holds each item still, protects it and presents it, so the box opens to an organised display. They are used for electronics, watches, gift sets, cosmetics kits and anything with several parts.
Every item in its place
Custom Rigid Boxes with Inserts
✓Clear proofing before productionSee our process
Get a free quote
Tell us what you are packing and we’ll reply with practical options.
Product features
Built around the jobFoam, board or wrapped rigid inserts
Multi-item layouts
Lift-off or magnetic lid
Finger notches and ribbon lifts
Printed or flocked insert tops
Item names under cavities
Swappable inserts per set
Specifications made for your product.
Technical snapshotEvery final specification is confirmed against product weight, packing method, print coverage, route, and order volume.
View artwork preparation guide- SKU
- bm-1054
- Dimensions
- Custom-made around the product and packing workflow
- Materials
- Wrapped greyboard, EVA or polyethylene foam, Paperboard or rigid board inserts
- Printing
- CMYK, Pantone, white ink, or unprinted
- Finishes
- Matte, gloss, soft-touch, foil, embossing, spot UV
- Quantities
- Starting at 100 on selected configurations
- Proofing
- Dieline and digital proof
Open to a perfect layout.
Artwork and materialsArtwork covers the box wrap, the inside lid and the insert surface. The insert is part of the presentation, so it can be printed or covered to match. Our packaging guides cover sizing, materials, print, and cost in more depth.
Wrap, inside lid and insert
We set your artwork on the box wrap and inside lid, and plan the insert surface as part of the design. Item names can sit under each cavity, and we keep print clear of cut edges so it stays crisp.
Explore print and finishesFoam, board or wrapped inserts
Foam holds items snugly and can be flocked or topped with a printed card, board inserts take direct print, and wrapped rigid inserts match the box paper exactly. Each gives the open box a different finish.
Explore material decisionsChoose your box
Tell us every item going in, its size and shape, and how you want the set to look.
Request a quote
We recommend the insert material and layout that hold your items and suit your box.
Finalize the order
Confirm the box, insert material, cavity layout, print areas and delivery details.
Build the dieline
We draw the box and insert around your items, with cavity depths and finger notches in place.
Approve the proof
Check the wrap, inside lid, insert print and every cavity position on the digital proof.
Roll on production
We make the boxes and inserts, check every cavity fit, and pack them for delivery.
Best for
Electronics and accessoriesWatches and jewelleryGift and cosmetics setsMulti-part kitsWhat changes the price.
Cost factorsEvery project is quoted individually. These are the choices that move the price on almost every order.
- Insert type
- Board inserts cost least, foam more, and wrapped rigid inserts the most.
- Number of cavities
- Each item needs its own cut-out, and complex layouts take more cutting.
- Printed insert
- A printed card top on foam, or a printed wrap on a rigid insert, adds a step.
- Box closure
- A magnetic lid costs more than a lift-off lid.
Buyer guidance
Choosing this format
Which insert suits a rigid box?
Foam for fragile items, wrapped rigid board for the most premium look, cardboard for light products and lower cost.
A foam insert cushions and grips, so it suits electronics, glass and watches. A wrapped rigid insert looks as finished as the box itself and suits jewellery and gift sets. A cardboard insert is light and low in cost, and suits cosmetics and small accessories.
- Foam: protection
- Rigid: premium look
- Cardboard: light and low cost
Designing a multi-item layout
Lay out the items in the order they should be seen, and leave enough material between cavities to keep the insert strong.
The hero product usually sits in the centre or on top, with accessories around it. A finger notch beside each cavity makes items easy to lift out. Measure each item at its widest, caps and cables included, since small differences there change the fit; we draw the cavities from those figures.
Box and insert, sized together
The insert is sized to the inside of the box, so both are drawn and proofed together.
A box sized first and an insert squeezed in later is a common source of lids that will not close. Drawing them together keeps the walls, the insert and the lid in step, and the digital proof shows the insert in place before anything is made.
Related packaging formats
Compare your options
Inserts
Fitted inserts that hold a product still, so it arrives as it was packed.
Explore box style
Rigid Boxes
Luxury two-piece and magnetic boxes with a substantial, keepsake feel.
Explore box style
Magnetic Boxes
Rigid boxes with a hidden magnet in the lid, for a deliberate first open.
Explore box styleQuestions about rigid boxes with inserts.
Box style FAQsWe’ll confirm the exact details that apply to your structure and volume.
Read all frequently asked questionsHow deep are the cavities in a rigid box insert?+
We cut each cavity deep enough to hold the item firmly, with the top left slightly proud so it can be gripped. Where an item sits low, we add a finger notch or a ribbon pull so it lifts out easily. We also make sure the tallest item clears the inside of the lid. Send us each item's measurements and we lay out the cavities.
Which insert is easiest to recycle with the box?+
A board insert. A folded board insert goes in paper recycling with the box, with nothing to separate. Foam inserts are plastic, so they come out and are handled on their own, but they grip glass and electronics more firmly. We recommend board where recycling matters most and foam where the product needs the most cushioning.
Can an insert be printed or covered to match the box?+
Yes. We can top foam with a printed card or flock it, wrap rigid inserts in the same paper as the box, and print board inserts directly. The insert surface is a good place for the name of each item under its cavity, or a short instruction. We keep print clear of the cut edges so it stays crisp.
Can one rigid box take different inserts for different product sets?+
Yes, as long as the inside size of the box stays the same. Many brands use one box with several inserts, for example a two-item and a three-item set, which keeps the costlier box the same across a range. We cut each layout to its own products and check that the lid closes cleanly on every version.
Do I need an insert if the product already fits the rigid box?+
Usually yes. We recommend one if the product is fragile, has several parts, or must look the same every time the box is opened, because without it items slide, scuff each other and arrive in a heap. A product that fills the box closely and cannot be damaged by movement, such as a folded garment, may need only tissue paper.
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