Product presentation and the ‘unboxing experience’ have always been major design considerations for retailers, no matter what products they offer. From consumer tech goods to stationery and even jewellery, all products need to be packaged at the end of the day.
But product packaging isn’t just an aesthetic demand. Products can easily become damaged in transit if their packaging doesn’t offer adequate protection from bumps, drops, and dings. This (in a neatly packed nutshell) is the value of packaging inserts.
At Vector & Raster Laser Services, our laser cutting technicians have produced plenty of custom laser cut packaging inserts for various products and industries. Today, we draw from our decades of experience to outline how you can go about designing and ordering custom laser cut packaging inserts for your own retail business.
What are Packaging Inserts?
Packaging inserts are basically any materials placed inside a product box to protect it and/or provide added value to the consumer (i.e. a printed flyer with more information on the product, etc.).
There are two different types of packaging inserts you’d consider for any product. These are:
- Protective structural inserts
- Promotional marketing inserts
Whilst promotional inserts typically take the form of flyers, brochures, or other two-dimensional printed materials, protective structural inserts are generally more likely to be three-dimensional. This is to ensure they take up enough volume in your product box to absorb impacts if the package were to be dropped or otherwise mishandled during transit.
Arguably, the best types of protective structural inserts are laser cut to fit the exact dimensions of your product. That way, the full volume of the box is filled, leaving no room for products to shift and accrue damage through movement while in transit.
Best Materials for Laser Cut Packaging Inserts
If you’ve ever unboxed any kind of consumer goods before, then you’ve absolutely already seen some examples of strong laser cut packaging inserts. But finding the ideal material for your own product packaging can still feel like quite a nebulous task.
Our laser cutting technicians recommend you start by considering these fan favourite laser cutting materials for creating your own custom protective packaging inserts:
Foam
Compared to other fill materials, foam maintains an exceptional weight to cost ratio, offering dense shock absorption whilst still maintaining a lightweight build. This is ideal for shipping and handling, as heavier parcels can rack up pricier postage fees for manufacturers and retailers.
The only downside of foam is that foam materials like polyurethane and EVA foam aren’t organic, being plastic-based materials. So whilst laser cut foam is considered to be a good option for cushioning fragile items like glass homewares or intricate electronics, these types of material inserts may not be suitable for eco-friendly brands looking to maintain their values.
Cardboard or Paper
Cardboard and paper materials are popular choices for packaging inserts as they’re similarly lightweight to foam inserts with the added advantage of being fully recyclable. Paper packaging inserts can come in the form of shredded paper, laser cut honeycomb paper, or flat sheets with laser cut folds so they can transition from two-dimensional to three-dimensional.
Similarly, cardboard inserts can either be laser cut on a cardboard sheet (so they’re shipped flat and are then folded into a three-dimensional design), or they can be laser cut as moulded pulp (so they’re pre-moulded and shipped stacked like cups). There are pros and cons to both, so it’s ultimately up to business owners to determine what cardboard insert style is best suited for their products and their budget, shipping, and warehousing requirements.
Plastic
Like moulded pulp cardboard inserts, plastic packaging inserts can be moulded using heat treatment to create a moulded design that fits the precise measurements of your products. Plastic packaging inserts can be made using a range of different plastic materials, spanning from PET (polyethylene terephthalate) and PVC (polyvinyl chloride) to polystyrene and other plastic-based foams.
Rubber
Rubber is a less common material found in consumer packaging due to its heavier weight when compared to foam, but it’s an insert material that still boasts high impact shock absorption. As rubber also maintains natural gripping and moisture-resistant properties, it’s suitable for keeping fragile products that are susceptible to vibrations firmly in place. This includes products like glass goods, delicate tools, and industrial or automotive parts.
The higher cost per unit of raw rubber materials makes them less likely to be found in consumer product packaging, but some brands may still use rubber coatings to enhance the shock absorbing properties of other plastic or foam packaging inserts.
How to Choose the Right Packaging Inserts for Your Products
To narrow down the list of packaging insert materials even further, be sure to consider these following details and how they relate to your own products and brand:
Your Product and it’s Protection Requirements
Products with delicate components naturally need well-designed protective packaging. If you’re concerned about your products being damaged in transit, then you’ll need to create packaging inserts that are specifically designed to ensure adequate protection and shock absorption for your product.
Your Brand Values
While it can be easy to secure laser cut plastic or foam packaging for your product boxes, these materials might not align with the values of your brand or your consumers. This is why manufacturers and retailers are encouraged to consider eco-friendly packaging options for their custom inserts.
Your Budget for Packaging Materials
Some packaging materials can boast higher cost per unit prices when compared to other materials. Similarly, heavier materials can leave your business with higher shipping and handling fees with your shipping partners. It’s well worth factoring in shipping and materials costs at scale when finding the right packaging solutions for your products.
Your Storage and Handling Requirements
Whilst foldable inserts can be stored flat and folded as needed, pre-moulded packaging inserts made using foam, plastic, or cardboard can make for an easier packaging experience for your warehousing and pick packer staff. For small businesses with limited time and resources for order fulfillment, moulded packaging inserts can help cut down on time and reduce risks of inserts being damaged by incorrect assembly.
Your Unboxing Experience
Finally, how do you want your products to be presented when your customers first open their package? Best case scenario is your product is front and centre, housed in perfectly custom cut packaging inserts that make a strong first impression. Do you want these inserts to have any custom designs like branding, logos, or playful text/copy on them? These presentation and branding aspects are also well worth considering to ensure your product is accompanied by a fantastic unboxing experience.
How to Order Your Custom Laser Cut Packaging Inserts
As mentioned, we’ve worked on a great variety of custom laser cut packaging insert projects in the past, so we’re proud to maintain an ordering process that’s streamlined and easily accessible to even the busiest small business owners and small batch retailers.
Simply follow this quick and easy 3-step process to order your custom laser cut packaging inserts.
Step 1 – Send Us Your Product Measurements and Dimensions
To start, give us some details about your products and what packaging requirements you might have for them, or may feel they need. You can either send us your product measurements and dimensions in written or typed format, or through sharing blueprints or diagrams outlining the exact shape of your product for precise measurements.
Step 2 – Select the Ideal Materials for Your Custom Packaging Inserts
From here, our laser cutting technicians and design team will mock up precise designs for your custom packaging inserts which are inclusive of any branding, logos, or other text or graphic designs you’d like to add onto your inserts using laser cutting or laser engraving technologies.
At this stage, we’ll also finalise your material selection and proceed with producing your custom packaging insert design in our laser cutting studio in Melbourne.
Step 3 – Pick Up Your New Inserts or Wait for Them to Arrive Securely in the Post
Once your custom packaging inserts are all ready and final designs are approved, you can then pick up your order directly from our studio, or simply await your order to be shipped directly to your business address. We ship Australia-wide, so you can rest assured knowing your custom packaging inserts will arrive at your business premises quickly and securely.
Perfect Your Packaging with Custom Laser Cut Packaging Inserts
At Vector & Raster Laser Services, we’re proud to offer a wide array of laser cut products to all of our customers, be they independent hobby creators or budding small business owners. With our custom laser cut packaging insert solutions, you can take all the panic out of your business’ packaging and shipping.
With our range of laser cutting materials, you can also find the perfect materials to protect your products and align with your brand values. Our laser cutting studios are also 100% powered by renewable energy, so it’s not just our outputs that will keep your company green – our processes will too!
Keen to know more about our custom laser cut packaging services? Then contact our team via our website or email today to inquire about our services or request a no-obligation quote on your next laser cutting project.
Laser Cut Packaging Inserts – FAQs
What materials can be laser cut for packaging inserts?
Foam, plastics, cardboard, paper, and rubber coated materials are most commonly used for producing laser cut packaging inserts.
What products benefit most from precision laser cut packaging inserts?
Delicate, fragile, or intricate products like consumer electronics, watches, jewellery, and products made from glass, china, or clay, can benefit greatly from being packaged with protective packaging inserts.
How do laser cut inserts differ from die-cut foam inserts?
While laser cut inserts feature heat-sealed edges, die-cut inserts use mechanical compression cuts instead, which produces a raw edge and/or a more concave curve produced by downward pressure of the mechanical moulding process.
Can laser cut inserts incorporate logos, branding, or engraved text?
Yes, laser cut inserts are 100% customisable, meaning that text or image-based branding can be incorporated into final designs.
What is the minimum order quantity for custom laser cut packaging inserts?
At Vector & Raster Laser Services, we’re proud to accommodate all of our small business partners, which is why our custom laser cut packaging insert services maintain no minimum order quantity. Even if you’re looking to produce a prototype packaging insert, our laser cutting technicians will be here to help.
How does a laser cut insert improve the unboxing experience?
Laser cut inserts help enhance the unboxing experience by:
- Providing customers with added value (i.e. through promotional or informative inserts like pamphlets)
- Creating a linear unboxing experience through creating chronological interactive layers that shape the customer’s first impressions of and interactions with the product
- Ensuring products arrive to the customer in an excellent condition every time
Are laser cut packaging inserts suitable for retail display and point-of-sale?
Yes, laser cut packaging inserts can easily be used in promotional retail displays and point of sale displays to securely showcase products without needing to remove them from their moulded, presentable packaging.
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