Custom Boxes with Foam Inserts
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Custom Boxes with Foam Inserts combine sturdy construction with fully customizable branding to help your products stand out. Free design support and fast turnaround available. Get your free quote today!
$0.55
UNLIMITED CUSTOMIZATION OPTIONS
A printing technique employing a plate to transfer designs onto paper. Ideal for extensive print jobs.
Plate-free digital printing transfers designs electronically, cost-effective for short runs.
Screen printing is a method using a mesh screen and stencil to transfer ink onto a substrate.
Quick-drying printing technique utilizing ultraviolet lights for ink curing, yielding a glossy finish.
Consisting of water-based pigments, Ensures top-notch color output with a 100% eco-friendly profile.
Fluorescent inks are vibrant, UV-reactive pigments that emit vivid colors under ultraviolet light.
Generate pure colors using specific ink formulas to consistently & precisely reproduce color in printing.
Produce metallic colors through precise ink formulations to replicate color in printing.
Premium bleached white paperboard, specially coated on one side to enhance printing & finishing.
Bleached white paperboard, coated on both sides to achieve superior printing quality and finishes.
Top-notch textured paper, perfect for adding a touch of style when wrapping up durable boxes.
A unique paper material showcasing a shiny or matte metallic laminated surface.
Bleached kraft paper crafted from a blend of new and recycled pulp, coated on both sides for optimal printing.
Kraft paper produced from a combination of new and recycled paper pulp, with coating on both sides for printing purposes.
Kraft paper dyed black, manufactured from a blend of new and recycled pulp, and coated on both sides for printing applications.
Crafted from recycled grey chipboard cardboard, also known as uncoated recycled paperboard, ideal for luxury rigid boxes.
Unique paper material showcasing a holographic laminated surface in either glossy or matte finish.
Grey chipboard, one-sided white cardboard with a smooth, printable surface, ideal for luxury rigid boxes.
Gloss lamination enhances visual appeal by applying a shiny finish, and protecting printed materials.
Matte lamination offers a non-reflective finish, providing elegant appearance to printed materials.
Made with a smooth lamination that feels like touching a peach, can choose between a satin or matte.
A UV coating is applied to a specific area and then cured using ultraviolet light to make it sturdy.
A transparent coating is applied using the CMYK printing technique, and it comes in gloss, satin, or matte.
A fast-drying coating that undergoes curing through ultraviolet light is offered in both gloss and matte.
In a printing method, dies are pressed onto the back of the material to create a raised motif.
A printing technique that involves pressing dies onto the front of the material to create a raised motif.
In foil relief printing, foil is transferred at high temperatures, often employing multiple colors.
Craft a die-cut shape with a plastic film layer, revealing a window to showcase the product inside.
We recommend the ideal material and add-ons like lamination, foiling, embossing UV, etc.
Get Free Design Support with your box 3d Renders or Send Your Design File for Printing.
Upon design approval, we’ll print and conduct quality checks before shipping the boxes to you.
Technical Specifications
| Dimensions | Available in Custom Sizes |
| Printing | CMYK, Pantone Color, Full Color & No Printing |
| Paper Stock | Eco-Friendly Kraft, Corrugated Cardboard & Premium Rigid Stock |
| Coating | Semi-Gloss AQ, Gloss UV, Matte UV & Spot UV |
| Default Process | Die Cutting, Gluing, Scoring, Perforating |
| Custom Options | Window Cut Out, Gold/Silver Foiling, Embossing, Raised Ink |
| Proof | Digital Proof, 3D Mock-Up |
| Shipping | Shipped FLAT (Free Shipping Across USA & Canada) |
| Help | For further inquiries and Quotes, contact us or email at sales@cratpackaging.com |
Custom boxes with foam inserts from Crat Packaging protect fragile, high-value or precision products in transit while keeping the unboxing experience premium. Each box is built with a die-cut foam interior shaped to your exact product, printed on the outside with your branding, and manufactured at our own US facility with free design support.
Key Features of Our Custom Boxes With Foam Inserts
- Precision-cut foam interior: shaped to your product’s exact dimensions to stop movement and impact damage
- Multi-density foam options: from soft polyethylene to rigid, high-density foam depending on product weight and fragility
- Fully branded exterior: CMYK or PMS printing, lamination and foil stamping on the outer box
- Custom cavity layouts: multiple compartments for kits, tool sets or multi-piece products
- Shock and vibration protection: reduces damage claims and returns on fragile or electronic goods
- Free die and foam-tooling setup: no extra charge to create a custom foam cavity shape
Specifications
| Box Style | Two-piece, mailer or rigid box with foam interior |
| Dimensions | Custom, matched to product and foam cavity |
| Material / Stock | Rigid chipboard or E-flute corrugated exterior |
| Foam Type | Polyethylene (PE) or polyurethane (PU), multiple densities |
| Printing | CMYK or PMS on exterior stock |
| Finishing | Matte/gloss lamination, foil stamping |
| Add-ons | Multi-cavity layouts, dividers |
| Minimum Order | See MOQ by material below |
| Turnaround | 10–15 business days (8-day expedited available) |
| Setup / Plate / Die Charges | Free |
Customization Options
Foam Density & Cavity Shape
We cut foam to your product’s exact silhouette, in a density matched to its weight and fragility — from delicate glassware to heavy tools.
Exterior Branding
The outer box carries full custom printing, lamination and finishing so protection never comes at the cost of presentation.
Multi-Piece Kits
Multiple cavities in a single foam layer keep kits, sample sets or component packs organized and secure.
Quality & Material Sourcing
Board weight, flute grade and film thickness are checked against your approved proof before a run goes into production, and again during finishing, so color, structural strength and add-ons match what you signed off on. If a spec needs adjusting once you see a sample in hand — a heavier stock, a different lamination finish, a tighter or looser fit — we can revise it before the full run ships, rather than after a large order has already been printed.
Industries & Use Cases
Electronics brands, precision tools, glassware and ceramics sellers, camera and optics companies, and subscription kit businesses use custom boxes with foam inserts to ship fragile or high-value products without damage.
How to Order
- Request a free quote with your box style, size, material and quantity.
- Get free design support and a digital proof from our team.
- Approve the proof — no plate or die charges, ever.
- Production begins, typically 10–15 business days (8-day expedited available).
- Your order ships to your US location, ready for safe transit of fragile items.
Why Wholesale Buyers Choose Crat Packaging
- Own US production facility — every box, including specialty stock, is made from scratch, never outsourced.
- No setup, plate, or die-cut charges on any order.
- Free design support from concept to print-ready proof.
- Low minimums and bulk pricing starting around $0.75 per unit, depending on size, material, quantity and finish.
- Standard 10–15 business day turnaround, with 8-day expedited production available.
Every order runs through our own quality checks before it ships, so the box you approve in the proof is the box that arrives. Because production happens at our own US facility rather than through a broker or outsourced print shop, our team can adjust a run mid-production, source a substitute stock quickly if a material is delayed, and give buyers a real answer on lead times instead of a generic estimate. That matters most for growing brands: a first order can start small, and reorders scale up on the same specs and pricing tier without renegotiating design or setup from scratch.
Frequently Asked Questions
What products need foam insert boxes?
Fragile, heavy or high-value items — electronics, glassware, tools, optics and multi-piece kits — benefit most from a custom-cut foam interior.
Can the foam have multiple compartments?
Yes, we cut multi-cavity foam layouts for kits and component sets at no extra design charge.
Is there a minimum order?
Yes, our standard MOQ for cardboard-based boxes is 100 units.
How is the exterior branded?
The outer box is printed in full CMYK or PMS color with optional lamination and foil stamping, just like our standard custom boxes.
What does foam-insert packaging cost?
Pricing depends on box size, foam density, cavity complexity and quantity — request a free quote for an exact number.
Have a spec that doesn’t fit a standard listing, or need a sample before committing to a full run? Our team is happy to talk through sizing, stock and finish options before you request pricing.
Protect what matters in transit. Request a free quote for custom boxes with foam inserts built around your product.
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