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How to Order Custom Box Inserts: A Spec Checklist
The difference between a quote that comes back in a day and one that stalls for a week is usually the brief. When we have the right information up front, we can design the insert, cut a proof, and price the run without a back-and-forth. When key details are missing, every step waits on a follow-up email.
This checklist covers the seven things we need to move fast. Gather them once, send them together, and you will have a design proof in 24–48 hours instead of a thread of clarifying questions.
The seven inputs we need
| Input | What to send |
|---|---|
| 1. Product dimensions | Length × width × height of each item, in mm or inches |
| 2. Product weight | Weight per item and total loaded weight |
| 3. Fragility | What breaks it; a G-factor if you have one |
| 4. Box / carton | Inside dimensions of the shipping box or case |
| 5. Material preference | Foam, board, or “recommend one” — plus ESD if relevant |
| 6. Quantity | Prototype count and expected run size (MOQ 25) |
| 7. Deadline | When you need parts in hand |
Get the dimensions right
Measure each product at its widest points and send length, width, and height. If items nest or stack, note that too. Just as important is the inside dimension of the box the insert has to fit — not the outside. A few millimeters of error here changes the whole cavity layout, so when a measurement is uncertain, tell us, or send a physical sample and we will measure it against our ±0.5 mm tolerance.
Describe weight and fragility together
Weight tells us how much the cushioning has to carry; fragility tells us how gently it has to stop. Send both. You do not need a lab-measured G-factor — a plain description works, such as “glass, cracks easily” or “sealed metal housing, rugged.” If the product must pass a specific drop or ISTA test, name it, and we will engineer to that target.
Send seven things: product dimensions, weight, fragility, the box’s inside dimensions, a material preference, quantity, and your deadline. With those in hand we can return a CAD proof in 24–48 hours and price the run in the same pass.
Tell us material, quantity, and deadline
If you know whether you want foam or board, say so; if not, ask us to recommend one and we will. Flag ESD needs early, since anti-static material changes the spec. On quantity, our minimum is 25, so send both your prototype count and the run size you expect — volume pricing improves as the run grows. Finally, give us a real deadline. Standard production is 7–10 business days after approval; if you are tighter than that, tell us up front so we can plan a rush.
Files help, but are not required
A CAD file or a dimensioned drawing speeds design, and a photo with a ruler for scale is genuinely useful. But none of it is mandatory. If you have no files at all, send us a sample product and we will measure and design from it. The point of the checklist is not paperwork — it is giving us enough to get the fit right the first time.
Have your specs ready?
Send the seven inputs and we will return a design proof and quote — usually within one business day.
Get a Custom QuoteKeep reading
Not sure which material to request? Read Foam vs. Cardboard Inserts: How to Choose. Shipping something fragile and want to understand how we engineer the cushion? See How We Spec Cushioning for Drop Tests. Or browse insert types on the products page before you brief us.