Rigid Box Inserts & Cavities | Printing Material

Millimetres and GSM measure different things

Millimetres describe thickness. GSM means grams per square metre and describes material mass per area. Two boards with the same GSM can differ in thickness and stiffness because their composition and density differ. Do not use a fixed GSM-to-mm conversion to order a rigid box. Ask for the core board thickness, board type and wrapping paper specification as separate lines.

Is 2 mm board right for my box?

Printing Material uses 1.4–2.2 mm Kappa core board. A request for 2 mm still needs the box dimensions, product weight, opening style and handling route to establish suitability. Review a loaded structural sample before approving the final board.

Choose an insert by function

The holder needs a removal path

A cavity that grips the product tightly may make it difficult to lift out. A finger recess, ribbon or accessible edge can help, depending on the item. In the pictured coin presentation box, the shaped holder defines the item space. Confirm the actual holder dimensions and removal method; the photo alone does not establish a material grade, anti-tarnish property or impact test.

Fabric, glass and sensitive products

Satin or velvet-like coverings can change the look and feel of a pack. They should not be treated as the only protection for glass. Bottles need appropriate restraint, and electronics may need product-specific protection requirements. For jewellery, do not assume a lining is anti-tarnish without supporting material information. Supply any contact, surface or handling requirements with the product brief.

Make environmental claims specific

A paper-based outer can still contain magnets, adhesives, coatings, foam and fabric. Avoid calling a complete pack plastic-free or fully recyclable unless the actual components and disposal route support that statement. If material separation or a paper-only direction is important, request it explicitly and review the construction options. Product protection and the receiving market's waste collection system also matter.

Material approval checklist

• Core board type and thickness, plus wrap and liner specification.
• Insert material, cavity layout and removal feature.
• Fit with the real product rather than an approximate substitute.
• Required material documentation and product-contact limits.
• Appearance of exposed edges, folds and covered corners.
• Packing and shipping protection for the complete order.

How to specify a custom inside cavity

Provide each complete product, including caps, sleeves and accessories, with its length, width, height and weight. Mark whether it will sit upright or flat, how much should remain visible, and where fingers or a pull ribbon can lift it. For a kit, identify the first item the recipient should see and remove.

Cavity depth, material thickness and spacing between items must work together. A deeper cut, layered construction, multiple product shapes or a fabric cover can increase material and assembly work. More cavities do not simply mean a larger version of a one-cavity insert. Compare these details through the rigid box cost guide.

Match the cavity to the use case

Perfume bottles need restraint around their actual shape and accessible caps. Jewellery needs a holder that presents small details clearly. Electronic kits need space for the device and accessories, with any product-specific material requirements confirmed. Welcome kits benefit from a repeatable arrangement that packing teams can assemble consistently.

Review the loaded insert inside the chosen drawer box or magnetic box. Check removal, lid clearance and movement before approval. For a fold-flat rigid box, confirm whether the insert also folds or must travel separately. See the sample approval guide for fit checks.

Questions before you order

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