Best Types of Die Cut Inserts for Custom Packaging
Author | Updated Date: 11/26/2025
Table of Contents
First impressions count—and die cut inserts make sure your products arrive safely and beautifully. Whether you’re shipping cosmetics, electronics, candles, or artisan items, using the right insert inside your box is the difference between a good experience and a great one.
Let’s explore why die cut inserts matter, their types, and how to choose the perfect one for your packaging.
What Are Die Cut Inserts?
Die cut inserts are protective packaging components custom-cut using precision dies to perfectly fit around your products. They act as tailored compartments—designed to stabilise, present, and protect.
These inserts are commonly used in:
- Cosmetics and skincare packaging
- Electronics and gadgets
- Food and bakery boxes
- Luxury and gift sets
They reduce movement, prevent breakage, and enhance the overall unboxing experience.
Why You Should Use Die Cut Inserts in Packaging?
Here’s what makes die cut inserts a smart choice:
- Prevent product shifting and shipping damage
- Keep multiple items separated and secure
- Elevate unboxing with neat presentation
- Support branding through custom shapes and materials
- Reduce customer complaints, returns, and losses
Best Types of Die Cut Inserts for Custom Packaging
1. Cardboard Die Cut Inserts (Most Common)
Best for: Lightweight to medium products like cosmetics, clothing accessories, candles.
- Cost-effective and rigid
- Custom shapes, sizes, and printing
- Fully recyclable and eco-friendly
- Available in white or Kraft brown options
✅ Packaging Tip: Add branding or product info directly on cardboard inserts for a polished internal look.
2. Kraft Paper Inserts (Eco-Friendly Favourite)
- 100% recyclable and biodegradable
- Earthy brown tone adds rustic charm
- Lightweight and cost-effective
- Ideal for homegrown brands and artisan packaging
3. Corrugated Inserts (Heavy-Duty Protection)
Best for: Heavy, breakable items like jars, electronics, and glassware.
- Multi-layer fluting provides cushioning
- Excellent for shipping long distances
- Can be layered or die cut with cavities
- Offers both strength and flexibility
Learn more about Corrugated Material →
4. Foam Inserts (For Luxury + Fragility)
Best for: High-end, fragile, or luxury products like jewellery, tech devices, CBD vials.
Types include:
- EVA (smooth, premium finish)
- PU (soft, flexible)
- EPE (durable and impact-absorbing)
- High cushioning and shock resistance
- Looks luxurious and feels premium
- Retains shape during multiple transits
✅ Packaging Tip: Combine foam inserts with rigid boxes for the ultimate luxury packaging experience.
5. Plastic Die Cut Inserts
Best for: Displaying products at retail (e.g. electronics, accessories).
- Transparent for visibility
- Lightweight and flexible
- Not biodegradable but long-lasting
- Often used in clamshell or folding carton packagin
6. Pulp Molded Inserts (Sustainable + Shock-Proof)
Best for: Tech gadgets, perfumes, delicate glass items.
- Made from recycled paper pulp
- Moulds around product shapes
- Excellent for sustainability-minded brands
- Home compostable and biodegradable
7. Foam Board Inserts (Premium Presentation)
Best for: Skincare sets, influencer boxes, luxury kits.
- Solid foam base with printable surface
- Supports detailed cutouts and logo shapes
- Sleek, clean aesthetic
- Often used in rigid drawer boxes and influencer kits
How to Choose the Right Die Cut Insert?
Not sure which insert suits your product? Consider these:
- Product weight & fragility
- Shipping environment
- Branding goals
- Eco-friendliness
- Packaging budget
Insert Customisation Options
Every detail matters in custom packaging—including your inserts.
Custom insert upgrades include:
- Logo embossing or laser-cut branding
- Colour-matching to your product or box
- Laminated finishes (matte or gloss)
- Dual-layered inserts for kits or sets
- Printed instructions or product info
Which Industries Use Die Cut Inserts the Most?
If your product is delicate, premium, or multi-part, die cut inserts are your best friend. Popular industries include:
- Cosmetics & skincare
- Electronics & gadgets
- Food & bakery packaging
- Jewellery & accessories
- Candle and home fragrance
- Gift sets & promotional kits
- CBD & wellness products
Why Work With a Professional Packaging Supplier?
Precision matters—especially when your packaging is protecting valuable goods.
At Buy Packaging Boxes, we provide:
- Fully customised inserts (size, shape, material)
- Fast UK-wide turnaround
- Expert design advice
- Competitive pricing on low and high volume runs
- Eco-friendly and luxury options available
Conclusion
The right die cut insert does more than just hold a product—it protects your brand’s reputation.
Whether you choose cardboard, foam, or pulp, investing in high-quality inserts:
- Prevents damage
- Enhances branding
- Delights your customers
Explore your packaging insert options today — because what’s inside your box should arrive looking perfect.
Quick Answers on Custom Inserts for Your Packaging
Cardboard is versatile and eco-friendly, while foam offers the best cushioning for luxury or fragile products.
They’re affordable, especially in bulk. The cost depends on material, size, and customisation.
Yes! We offer low MOQs on select insert styles. Get in touch for a quote.
For fragile or high-end items—yes. For general use, cardboard is cost-effective and recyclable.
Yes, especially options like Kraft, pulp moulded, and cardboard inserts.
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