You can create inserts to place inside your packaging, acting both as a raised base for the product and as a locking element.

The insert is created from a sheet of paperboard folded on all four sides, and you can add custom cutouts shaped to match the product. These cut-outs are used to position the product and secure it inside the box.

Please note: the insert is a standalone product, to be configured and ordered separately from the box.

How to calculate the insert's dimensions

Start from the dimensions of the product (or products) to be housed and calculate the distances to keep between the cutout and the edges of the insert, and between one cutout and another. These measurements affect the external dimensions of the box, because the insert has to fit inside it.

Recommended margin around the product (per side):

  • Paperboard: 10 mm
  • Corrugated cardboard: 15 mm
  • Recommended height of the insert: half the height of the product.

Example: a cube-shaped product measuring 30x30x30 mm, paperboard insert.

  • Base: 30 mm (product) + 10 mm margin per side = 50x50 mm
  • Height: half of 30 mm = 15 mm
  • Insert dimensions: 50x50x15 mm

With corrugated cardboard, the same product requires a margin of 15 mm per side.

For the cardboard insert, you can use the same internal dimensions as the box. For models such as the rollover hinged lid box, however, we suggest to consider a small margin of tollerance: the closing flaps of the box, sit between the insert and the side walls, so if the insert is exactly the same size, it may lift up the insert when the box is opened.

How to order the insert on Packly

  • Select the Insert product and set the dimensions and material.
  • Select the Windows and die-cuts option and specify the number of elements to add (maximum 9).
  • Download the dieline and add the cut-outs to the insert, as described in the next section.
  • Upload the file back onto the creation page: the change will be visible in the 3D preview.

If your project requires more than 9 elements, contact our support team to check feasibility.

How to add a cut, crease or perforation

Each element is added to the dieline using a spot colour that indicates its type. The name of the colour must be exactly one of the following:

Custom-Cut for a cut-out

Custom-Crease for a crease line

Custom-Perf for a perforation line

  • Open the downloaded dieline in a vector graphics software, such as Adobe Illustrator.
  • Create a new spot colour and name it according to the element you want to add.
  • Set the spot colour to 100% and activate overprint.
  • Draw the cut, crease or perforation using this colour, without modifying the original lines of the dieline.
  • Save the file as Adobe® PDF preset "high quality", in CMYK mode, and upload it back onto Packly to check the 3D preview.

To see the cut-out as an opening in the 3D preview, use Custom-Cut as the fill of the shape.

During production, the cut-out may not detach completely: small retention points may remain. For file details, please refer to the guidelines.

Minimum distances to observe

Paperboard: at least 10 mm from the dieline and 10 mm between one element and another.

Corrugated cardboard: at least 15 mm from the dieline and 15 mm between one element and another.

Minimum size of the cut-out: a circular hole must have a diameter of at least 3 mm. A rectangular cut-out must have a width and depth of at least 3 mm.