Custom Inserts in Montpelier, VT

Custom packaging inserts transform the interior of a standard box into a precisely engineered product presentation system — securing items against movement during shipping, presenting products at the optimal viewing angle for unboxing, and communicating brand values through the materials and precision of the insert design itself. Our custom inserts are manufactured from a range of materials calibrated to the product's weight, fragility, and presentation requirements.

Insert Material Options

• EVA Foam: The most versatile insert material — CNC-cut to any product profile in densities from 1.2 to 6.0 lb/ft³. Used for electronics, jewelry, cosmetics, medical devices, and precision instruments
• Polyethylene Foam: Standard protective foam for heavier products and shipping applications — excellent shock absorption and compression resistance
• Corrugated Cardboard Inserts: Die-cut corrugated dividers and partitions for multi-unit packaging — cost-effective and recyclable
• Thermoformed Plastic Trays: Precision-formed PET or PVC trays with individual product cavities — standard for cosmetics, electronics, and food packaging
• Molded Pulp: Sustainably produced from recycled paper fiber — used for premium electronics, wine, and fragile product inserts as a plastic-free alternative
• Velvet-Flocked Foam: EVA foam with velvet flock coating for jewelry and luxury goods presentation

Insert Design Principles

Effective insert design begins with the product's center of gravity and fragility points. The insert must prevent movement in all six directions during shipping while presenting the product face-up at the correct angle for unboxing. For multi-product packaging, the insert must maintain consistent product spacing regardless of manufacturing tolerance variation in individual product dimensions.