Custom Foam Inserts for Boxes and Kits

What custom foam inserts are

A custom foam insert is a piece of foam cut to the inside of a box, with a cavity shaped for each product. The products press into their cavities and sit in a fixed layout, which keeps a multi-item kit organized and makes the box look arranged when it opens. Buyers also call this custom foam packaging or die cut foam inserts.

The foam is chosen for the job. Closed cell EVA and polyethylene foams are firm and keep a clean cut edge, while open cell polyurethane foam is softer and often lines a lid. We quote inserts in EVA, polyethylene, laminated polyethylene, polyurethane, polypropylene and expanded polystyrene (EPS) foam. The insert is designed around the box it goes in, so it is usually quoted with that box.

Three foam insert samples: black closed-cell foam with cutouts, white foam with cutouts and grey convoluted foam

Get a custom foam insert quote

Add the dimensions of each item, the box size, the quantity and whether you also need the box. We confirm the foam and layout options and the cost in your quote.

Foam insert layouts for boxes

Most custom foam inserts for boxes fall into one of these layouts. Many kits combine a base insert with a lid pad.

Inserts for rigid and magnetic boxes

A foam layer cut to sit flush in the base of a rigid box, with one cavity per item, so a kit opens arranged.

Custom Rigid Boxes

Inserts for shipping boxes

Foam cut to the inside of a printed mailer or carton, so products travel in a fixed layout from packing table to doorstep.

Custom Printed Shipping Boxes

Lid pads and liners

A soft foam pad for the lid or a thin liner for the walls, used together with a cut base insert.

EVA foam inserts

EVA foam inserts are a common pick for retail and presentation kits because the foam is dense, has a smooth surface and holds sharp cavity edges. It suits beauty sets, device kits and gift boxes where the insert is seen. Pair it with custom magnetic boxes or a lid and base rigid box for a premium kit. If you prefer another foam, say so in your request.

How ordering works

Step 1
Measure each item
Length, width and height of every item that goes in the box.
Step 2
Share the box
Inside dimensions of the box, or ask us to quote the box too.
Step 3
Add quantity and layout
How many boxes, your delivery ZIP and a photo or sketch of the layout.
Step 4
Get your quote
We confirm the foam, layout options and the cost.

Pricing and order details are confirmed in your quote. For cold shipments, the foam insert holds the product while gel packs for shipping and an insulated shipper handle the cold side.

Foam types for box inserts

We quote inserts in EVA, polyethylene, laminated polyethylene, polyurethane, polypropylene and expanded polystyrene (EPS) foam. The table gives general descriptions of the three used most in box inserts. Tell us your foam preference or we will suggest one.

	EVA foam	Polyethylene (PE) foam	Polyurethane (PU) foam
Cell structure	Closed cell	Closed cell	Open cell
Feel	Dense, smooth surface	Firm, lightweight	Soft and flexible
How cavities are made	Die cut or cut to shape	Die cut or cut to shape	Die cut, or convoluted egg crate sheets
Typical use	Retail and presentation kits	Shipping boxes and repeat programs	Soft lining and lid pads

Who uses custom foam packaging inserts

We quote custom foam inserts for boxes that ship or sell these products. We do not name customers on this page.

Beauty and skincare

Inserts that hold bottles, jars and droppers upright in a gift set or launch kit.

Electronics accessories

Cutouts for devices, chargers and cables inside a retail or kit box.

At-home test kits

Inserts that keep vials, swabs and devices in their own places in the box.

Food and beverage gifts

Inserts for jars and bottles, with gel packs and an insulated shipper quoted for cold contents.

Subscription and welcome kits

The same layout every cycle so each kit is packed the same way.

One quote for the box, insert, gel packs and shipper

An insert is one layer of the pack-out. One quote covers the insert, the printed mailer, a liner or EPS shipper, and the gel packs.

Printed boxCustom Foam Inserts for Boxes, printed to your artwork
Foam insertCut to the items in each box that hold each item in place
Gel packsGel packs for shipping for the pack-out
Insulated or EPS shipperInsulated shipping boxes or styrofoam shipping coolers

Tell us what you ship, the box size and how each order is packed, and we will quote the pieces together so you deal with one contact. Test your complete pack-out before regular use.

Custom foam insert questions

What are custom foam inserts for boxes?

Custom foam inserts for boxes are foam pieces cut with a cavity shaped for each item, so the products sit in a fixed layout inside the box. They are used in shipping boxes, retail boxes and kit boxes. The insert is sized to the inside of the box and to the items that go in it.

Which foam should I choose for an insert?

EVA foam is dense with a smooth surface and suits presentation kits. Polyethylene foam is firm and lightweight and is common in shipping boxes. Polyurethane foam is soft and open cell and is often used as a lining or lid pad. We quote EVA, polyethylene, laminated polyethylene, polyurethane, polypropylene and expanded polystyrene (EPS) foam. Tell us what you pack and any foam preference, or we will suggest one.

Do you make inserts for gun or hobby cases?

This page covers inserts for shipping, retail and kit boxes that brands pack and send to customers. If your project is a box program like that, send the item and box sizes. For a single case or a hobby project, a case foam specialist is likely a better fit than our quote process.

Can you supply the box and the insert together?

Yes. Most insert projects are quoted with the box they go in, such as a rigid box, a magnetic box or a printed mailer. Tell us the box style you have in mind, or send the item sizes and we will suggest a box and insert combination in the same quote.

What should I send for a foam insert quote?

Send the length, width and height of each item, how many items go in each box, the box size if you already have one, the quantity of boxes and your delivery ZIP. A photo or sketch of the layout helps. We reply with the foam and layout options we can supply and what they cost.

Custom Rigid BoxesSet-up boxes with a printed wrap for kits, gifts and premium products.Custom Magnetic BoxesRigid boxes with a hinged lid that closes with hidden magnets.Styrofoam shipping coolersEPS coolers with corrugated outer cartons, sold by the case.Gel packs for shippingGel packs quoted with your boxes for perishable shipments.

Ready to quote your custom foam inserts?

Send the item sizes and the box they go in, and we will price the insert and box together.

Custom Foam Inserts for Boxes