The right packaging insert holds the product in place, protects it in transit and completes the unboxing. The main options are EVA foam, sponge, EPE foam, blister trays, paper pulp and cardboard. Choose by product weight and fragility, the look you want, budget and sustainability goals.
Key takeaways
- EVA gives a soft, precise, premium look for gifts, cosmetics and electronics.
- Sponge and EPE give the most cushioning for fragile or heavy items.
- Paper pulp and cardboard are paper-based, recyclable options that flatten well.
- Send product samples or CAD so inserts are cut to fit within tolerance.
Insert types compared
| Insert | Protection | Look and feel | Sustainability | Best for |
|---|---|---|---|---|
| EVA foam | Good | Soft, precise, premium | Plastic-based | Cosmetics, jewelry, electronics |
| Sponge | High cushioning | Basic | Plastic-based | Fragile or heavy items |
| EPE foam | High cushioning | Basic to neat | Plastic-based, recyclable in some regions | Fragile products, shipping protection |
| Blister tray | Good shape hold | Clean, molded | Plastic-based | Sets of small items |
| Paper pulp | Good | Natural, molded | Paper-based, recyclable | Eco brands, electronics, bottles |
| Cardboard | Moderate | Clean, printable | Paper-based, recyclable | Light products, dividers, flat shipping |
Each type explained
EVA foam
EVA is cut or molded with a smooth finish and can be color matched. It lines rigid boxes elegantly and is a favorite for premium gifts.
Sponge and EPE
These absorb shock. EPE foam is light and resilient; sponge is dense and soft. Use them for fragile items or when parcels face rough handling.
Blister trays
Vacuum-formed trays hold small items in fixed positions, ideal for sets and kits.
Paper pulp and cardboard
Molded pulp and die-cut cardboard replace plastic where possible. They also support flat shipping and responsible sourcing; see paper-based packaging trends.
How to choose an insert
- Weight and fragility: heavy or fragile items need EPE, sponge or thick EVA.
- Brand look: premium products benefit from EVA or velvet-covered inserts.
- Sustainability: choose pulp or cardboard if reducing plastic is a goal.
- Shipping: flat inserts suit lower freight cost.
- Budget: cardboard and simple foam are most economical.
Design tips
- Provide product samples or 3D files for precise cavities.
- Allow a small tolerance so products slide in easily but do not rattle.
- Add a finger notch or ribbon pull for easy removal.
- Pair with the right box: collapsible rigid boxes and lid and base boxes both accept fitted inserts.
Browse our custom packaging inserts.
Frequently asked questions
Which insert is best for a premium look?
EVA, often covered or color matched, gives the most refined, premium appearance.
Which insert is the most eco-friendly?
Paper pulp and cardboard are paper-based and recyclable, so they are the most sustainable choices.
Which protects fragile products best?
EPE foam and sponge provide the highest cushioning.
Can inserts be customized to my product?
Yes, cavities are cut or molded to your product dimensions.
Do inserts affect shipping cost?
Yes. Thick foam adds volume, while flat pulp or cardboard inserts keep packs compact.
Need a fitted insert?
Send your product sample or size and we will propose the right material.
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