A corrugated retail display box that ships flat and folds up into a counter display with a standing header card. The tray holds and faces your products at the point of sale while the header carries branding above them. Printed full color for shelf and checkout promotions, launches, and sampling.
An E-flute corrugated mailer with a full-color printed interior and an all-paper die-cut insert that cradles every part with no plastic. Plain kraft outside, branded reveal inside. Built for bathroom and sanitary kits shipped direct to customers.
Custom corrugated mailer box with tab lock roll end structure, self-seal adhesive closure, and tear strip opening. Available in kraft or printed finish, with optional inserts for organized packing.
The custom die-cut foam insert is a black EPE foam tray cut to the exact shape of your product, so tools, hardware, and electronics sit locked in a fitted pocket and ride protected from shock and abrasion. As a product packaging foam insert it drops into a color box, mailer, or case, and as an industrial foam insert it holds heavier parts square through handling and transport.
| Option | Standard (as shown) | Customizable range |
|---|---|---|
| Type | Die-cut EPE foam insert | Top and bottom set, laminated, dual-side cavity |
| Material | Black EPE foam | EVA, PU, EPS, anti-static, colored |
| Cavities | Contoured to each part | Any product and layout |
| Density | About 25-30 kg/m3 | Configurable to item weight |
| Thickness | Built to the nest depth | Single sheet to laminated blocks |
| Cutting | Die-cut, CNC, or hot-wire | - |
| Fit | Drops into mailer, color box, or case | Sized to the carton |
| Surface | Non-abrasive closed-cell | Flocked, film-faced |
| Tooling / MOQ | Configurable, no strict minimum | - |
| Lead time | Configurable to order | - |
Each pocket is die-cut, CNC-routed, or hot-wire cut to one part, so the item sits deep and square with no rattle, pressure marks, or contact between pieces. A tool case foam insert can hold a full kit with cut-outs for each tool and accessory, while a top-and-bottom set locks a heavier product from both sides. Send a sample or a drawing and the sample room cuts the cavities and depths to your product.
EPE is the default: resilient, light, moisture-resistant, and cost-effective. For a firmer, high-end tool case we run EVA, which holds a crisp cut and a soft-touch look, and for very soft cushioning we run PU. Electronics get an anti-static grade so the same protective foam packaging also drains charge. Tell us the product, weight, and finish and we advise the foam.
EPE is an expanded polyethylene foam that is soft, resilient, and recovers after impact, so it absorbs drops and vibration that would crack a brittle white foam. It does not shed dust and will not scratch a plated, painted, or polished surface, which suits hardware and appliances. It is light and water-resistant, so protective foam packaging adds cushioning without much weight and shrugs off damp transit.
Use the industrial foam insert for hand and power tools, faucets and hardware, valves and fittings, instruments and gauges, small appliances, and consumer electronics with accessories. The contoured pockets hold each part and its extras, the soft foam takes courier and forklift knocks, and the black bed presents a clean, professional pack for retail and export.
Send your product, a sample or drawing, the accessories it ships with, and the box or case it sits in, and we will cut a dieline and quote the insert with a sample for your approval. ISO 9001 and 14001 systems keep density, cavity fit, and cut quality consistent lot to lot, so every insert holds the product the same.
Can you fit it to any product shape? Yes. Send a sample or a drawing with the dimensions of the product and its accessories, and we die-cut, CNC-rout, or hot-wire cut the pockets to fit, then send a sample to check before tooling. Single tray, top-and-bottom set, or laminated tiers are all possible.
EPE, EVA, or PU, which foam should I use? EPE is the resilient, cost-effective default for most products. EVA is firmer with a crisp, premium look for high-end tool cases. PU is softer for delicate items. Tell us the product weight, fragility, and finish and we advise the grade, or combine them in one pack.
Do you make an anti-static version for electronics? Yes. The same insert comes in pink anti-static or black conductive foam, quoted to the surface-resistance band your ESD program needs, so sensitive boards and devices get both cushioning and static protection in one piece.
What is a realistic order quantity? There is no strict minimum, but the die and foam setup spread over the run, so small batches cost more per piece and price drops with volume. Tell us your annual volume and we advise the break points.
