The insert is the part of the box your product actually touches. It decides how safely the product travels and how it looks when the box is opened. This guide compares the most common insert materials for rigid boxes, so you can choose the right one.
EVA foam inserts
EVA (ethylene-vinyl acetate) foam is a dense, flexible foam cut precisely to the shape of your product.
- Protection: excellent. It absorbs knocks and holds heavy items tightly.
- Look: clean and modern, usually black or white.
- Best for: glass perfume bottles, electronics, tools, watches and heavy gift items.
- Consider: EVA is a plastic, so it is less easy to recycle than card.
Card inserts
Card inserts are made from folded and glued paperboard, sometimes printed.
- Protection: good for lighter products, especially when well fitted.
- Look: neat and minimal, and it can be printed in your brand colour.
- Best for: cosmetics, skincare, sets and brands focused on recyclable packaging.
- Consider: card does not compress, so it needs a slightly more generous fit.
Velvet-covered inserts
A foam or board insert covered in velvet or flocked material.
- Protection: as good as the core underneath.
- Look: soft, rich and luxurious.
- Best for: jewellery, watches and high-end gift editions.
Satin lining
Satin draped or padded inside the box, often with a cut-out for the product.
- Look: classic and elegant.
- Best for: perfume and gift sets where a traditional luxury feel matters.
Moulded pulp inserts
Moulded pulp is made from recycled paper fibre pressed into shape.
- Protection: good, especially for irregular shapes.
- Look: natural and textured, with an eco-friendly feel.
- Best for: sustainable brands and large runs.
- Consider: it needs a custom mould, so it suits large quantities better than small runs.
Side-by-side comparison
| Insert | Protection | Luxury look | Recyclable | Small runs |
|---|---|---|---|---|
| EVA foam | Excellent | Modern | Harder | Yes |
| Card | Good | Minimal | Yes | Yes |
| Velvet-covered | Excellent | Very high | Harder | Yes |
| Satin lining | Fair | High | Harder | Yes |
| Moulded pulp | Good | Natural | Yes | Better for large runs |
Which should you choose?
- Heavy glass bottle that ships by courier: EVA foam.
- Eco-focused skincare set: printed card.
- Jewellery or watch: velvet-covered.
- Traditional luxury perfume: satin lining or velvet.
Getting the fit right
Whatever material you choose, the fit matters most. Send us the size and shape of each item, ideally with photos next to a ruler. Our rigid box dimensions guide explains the tolerances we add.
See all the options on our rigid boxes with inserts page, or send your product details through Get a Quote.
