Product Overview

Our custom insert two-piece gift boxes combine a separate lid and base structure with tailored interior packaging designed around the product. Custom-fit inserts help organize products, reduce movement and create a more secure and professional presentation.

Custom insert options can be developed based on your product dimensions, weight distribution, and transit requirements. Depending on the application, interior protection solutions include EVA foam, paperboard, high-density EPE, or custom-molded interior structures.

Key Features of Custom Insert Two-Piece Gift Box

01/

Custom Interior Engineering: CNC-milled or die-cut inserts contoured precisely to your product geometry.

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Controlled Lid Friction: Engineered air clearance between lid and base to ensure smooth opening and secure closure.

03/

Structural Rigidity: Heavy-duty chipboard construction prevents collapsing under stacking pressure during ocean freight.

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Surface Protection: Soft-touch linings, velvet flocking, or anti-scratch coatings protect delicate product finishes.

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Precision Registration: Automated wrapping and corner-staying ensure sharp 90-degree edges and aligned printing lines.

Box Structure

Structural Parameter	Technical Specification / Options
Box Style	Two-Piece Rigid Box (Lid and Base / Telescope Box)
Lid Depth Options	Full-depth lid, partial-depth lid, or shoulder/neck style
Greyboard Thickness	1.5mm (1000gsm), 2.0mm (1200gsm), 2.5mm (1500gsm), 3.0mm (1800gsm)
Corner Construction	V-cut / V-grooving for sharp corners, tape corner staying
Wall Thickness Tolerance	Plus or minus 0.5 mm
Friction & Fit Control	Calibrated air-gap spacing for precise lid lifting resistance

Materials of Custom Insert Two-Piece Gift Box

Component	Standard Material Options	Characteristics & Function
Outer Wrap	128gsm / 157gsm Art Paper	Smooth printing surface for offset graphics and foil stamping
	Specialty / Textured Paper	Premium tactile grain, dyed fibers, high tear resistance
	Kraft Paper (Brown / White)	Natural texture, recyclable, high tensile strength
Rigid Core	Solid Recycled Greyboard	Structural integrity, flat surface, warp-resistant density
Inner Lining	Uncoated Paper, Velvet, Satin	Conceals internal seams and coordinates with the insert color

Printing & Finishing

Surface Treatment	Process Details	Performance Specification
Printing	Offset Printing	CMYK, Pantone Spot Color matching (Delta E under 1.5)
Lamination	Matte, Gloss, Soft-Touch / Velvet Film	Scratch resistance, moisture protection, scuff suppression
Stamping	Hot Foil Stamping	Gold, Silver, Rose Gold, Holographic, Matte Foils
Embossing / Debossing	3D Brass Die Pressing	Precise tactile depth and sharp edge definition
Varnish / Coating	Spot UV, Raised UV, Soft-Touch Varnish	High-contrast gloss accents on matte backgrounds

Custom Insert Options

EVA Foam Inserts

Suitable for: Fragile products, glass bottles, small electronics, premium accessories, precision industrial parts.
Material Properties: Closed-cell structure, high shock absorption, oil resistance.
Density Range: 38 to 45 shore hardness for standard protection; 55 to 70 for heavy equipment.
Surface Upgrades: Velvet flocking layer, synthetic leather top layer, or laser-engraved branding on foam surface.

Paperboard & Cardboard Inserts

Suitable for: Retail products, multiple SKUs, lightweight items, eco-focused packaging requirements.
Material Properties: Recyclable, foldable structure, flat-pack shipping options to reduce storage space.
Types: Folded card bridge inserts, die-cut corrugated trays, partitioned paper dividers.

Custom Compartments

Suitable for: Product collections, cosmetics sets, corporate gift bundles, multi-piece tools.
Design Features: Multi-level stepped cavity layouts, custom finger notches for easy product removal, integrated ribbon pulls.

Insert Type	Material Options	Processing Method	Primary Function
EVA Foam	High-density EVA, High-elasticity EVA	CNC Milling, Laser Cutting, Die-Cutting	High impact protection, vibration damping
EPE / PE Foam	Expanded Polyethylene	Heat Lamination, Die-Cutting	Cushioning for medium-weight items
Cardboard / Folding Boxboard	300gsm - 450gsm Art Card, Kraft Paper	Die-Cutting, Machine Scoring & Folding	Eco-friendly partitioning, color-matched background
Plastic Trays	PET, RPET	Vacuum Thermoforming	Clear contour matching, moisture resistance

Applications of Custom Insert Two-Piece Gift Box

Consumer Electronics: Holds wireless earbuds, smartwatches, and charging cables in dedicated cutouts without movement.

Cosmetics & Skincare: Secures glass serum bottles, cream jars, and droppers, preventing impact breakage during delivery.

Liquor & Beverage: Supports heavy glass bottles using high-density foam reinforced by thick paperboard walls.

Luxury Apparel & Accessories: Holds cufflinks, leather goods, belts, and tie sets using velvet-flocked interior compartments.

Corporate & Event Gifts: Combines notebooks, pens, power banks, and flash drives within a single organized layout.

Customization Options

Custom Dimensions

Length, width, and height manufactured to exact product specifications.

Structural Dielines

Vector dielines provided within 24 hours for graphic layout placement.

Closure Accessories

Integrated ribbon pull tabs, embedded magnets, elastic bands, or sleeve covers.

Insert Surface Finishes

Flocked velvet, satin fabric covers, soft synthetic leather wrapping, printed paper card overlays.

Quality Control

Test / Inspection Item	Testing Method	Acceptance Standard
Dimensional Tolerance	Digital Caliper Check	Insert Cavity: Plus or minus 0.3 mm; Box Outer Size: Plus or minus 0.5 mm
Color Accuracy	Spectrophotometer Measurement	Delta E under 1.5 against approved color proof
Adhesion Strength	Cross-Hatch Tape Test	Zero peeling on laminated film, foil, or print ink
Drop Protection	Free-Fall Drop Test	Transit protection verified under standard drop testing rules
Moisture Content	Pinless Moisture Meter	Greyboard moisture maintained between 8 percent and 12 percent

OEM / ODM Manufacturing Process

Requirement Analysis: Product files or physical samples received for dimension measuring.

Structural Prototyping: Physical sample and unprinted insert created via CNC cutting tables for fitting verification.

Graphic Approval: Digital proofing and physical color samples confirmed prior to mass production.

Mass Production: Automated die-cutting, greyboard V-grooving, wrapping, insert assembly, and gluing.

Quality Check & Packaging: Final dimensional check, vacuum dusting, moisture pack insertion, and master carton packing.

FAQ

Q: What file formats are required to design the custom insert?

A: STEP, IGES, or vector AI and PDF files containing exact three-dimensional dimensions of your product are preferred. Physical samples can also be measured directly in our facility to build accurate dielines.

Q: How do you prevent foam inserts from odor inside sealed boxes?

A: We use odorless, high-grade EVA foam materials that undergo a forced aeration curing process before box assembly, ensuring compliance with indoor air quality standards.

Q: What greyboard thickness is recommended for heavy products?

A: For products weighing over 2 kg, a 2.5 mm (1500 gsm) or 3.0 mm (1800 gsm) rigid greyboard core is recommended to maintain structural integrity under stacking pressure.

Q: Can insert trays be designed for easy product removal?

A: Yes. Cutouts can include ribbon pull tabs, finger notch cuts, or sloped cavity walls to allow users to lift products effortlessly.

Q: What is the typical lead time for custom structural prototypes and mass production?

A: Physical unprinted structural samples require 3 to 5 business days. Mass production typically requires 12 to 18 business days after sample approval and deposit confirmation.

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