Custom Welcome Kit Boxes

How a welcome kit box comes together

A welcome kit is a box plus an insert, and the insert is where most of the design work goes.

The outer box is usually a self-locking corrugated mailer, which ships flat and closes without tape, or a rigid box with a lift-off or magnetic lid. Either one is then fitted with an insert that holds each item in a set place.

Inserts are commonly die-cut card or corrugated with cut-outs shaped to each item, or a foam tray for heavier or more delicate pieces. Without an insert, items slide around and the box arrives looking like a pile rather than a kit.

• Mailer or rigid outer box
• Insert gives each item a place
• Card, corrugated or foam inserts

Planning the layout

Lay the real items out first and design the box around them, not the other way round.

Start with the largest and heaviest item, such as a bottle or a hoodie, then place the smaller pieces around it. A folded t-shirt can sit flat under a tray, which saves height. Leave a little space around each cut-out so items lift out easily.

Kit items often come from several different places, so the exact items need to be final before the insert is cut. A bottle that changes shape or a notebook that grows by a few millimetres will not fit an insert made for the old one. Send us the sizes of the final items and we draw the insert around them.

• Place the largest item first
• Fix the items before cutting the insert
• Leave room to lift things out

Mailer or rigid box?

A mailer is the practical choice for posting kits. A rigid box is for kits handed over in person or kept on a desk.

Corrugated mailers are light, strong enough for the post, and flat until packed, which matters when kits are sent to people working from home. The inside can be printed with a welcome message for the moment the lid opens.

Rigid boxes feel more substantial and are often kept as desk storage, which keeps the brand in view. They take far more storage space and usually need an outer carton to travel safely by post.

Print and the opening moment

The inside of the lid is the first thing a new starter reads, so it is worth using.

A short message, a QR code to a welcome page or a simple pattern inside the lid makes the kit feel considered. On a mailer, the inside is printed on the same flat sheet as the outside, so it can be added without a separate run.

Keep the outside simple if kits are posted. A clean logo travels well, and a plainer outer box draws less attention on a doorstep than one that clearly holds branded goods.

Packing and sending at scale

Kits are packed by hand, so the design should make packing quick and the result the same every time.

Each extra item is another step at the packing table. Inserts that show clearly where each piece goes make packing faster and cut down on missing items. A welcome card that slots into a set place is easier than one tucked in loose.

If kits go out over months rather than all at once, think about storage. We deliver mailers and inserts flat, so they take little room until needed, while rigid boxes made up in advance take a lot.

Fitted kit box or plain mailer?

A fitted kit box is the right pick when every kit holds the same items. A plain mailer is the right pick when the contents change from kit to kit.

If each kit holds different items, such as sizes of clothing or choices of gift, a single insert will not fit them all. A plain mailer box with tissue or crinkle paper copes better with variety, and we can print it to match the rest of the welcome range.

For one or two small items, a full kit box is more packaging than the contents need. A slim mailer or a padded envelope with a printed card does the job with less waste and lower postage.