Begin with real product dimensions
Use measured product dimensions, weight, center of gravity, tolerances and fragile points. Nominal capacity or a product photo is not enough to engineer a secure fit.
Paper and molded pulp
Folded paperboard inserts offer printability and recyclability. Molded pulp supports complex forms and plastic reduction, but tooling, surface texture and dimensional tolerance must suit the product.
Foam and fabric-covered inserts
EVA and other foams provide cushioning and precise cavities. Fabric or paper wrapping improves presentation. Density, thickness, odor, color transfer and adhesive performance should be sampled.
Test the complete pack
Evaluate insertion and removal, shake movement, compression, drop risk and the outer shipping carton—not only the insert on a desk. Final performance depends on the complete packaging system.