EVA vs card inserts: which should you choose?

An insert holds your product in place, protects it in transit and makes the unboxing look deliberate. The two most common choices are EVA foam and card. Here is how to choose.

EVA foam inserts

EVA is a dense, closed-cell foam. Cavities are cut to the exact shape of your product.

Strengths

• Excellent grip and cushioning for heavy or fragile items such as glass bottles and electronics.
• Clean, premium look, especially in black or wrapped in velvet.
• Holds odd shapes precisely.

Trade-offs

• It is plastic foam, so it is harder to recycle than card.
• Cavities are cut for one product shape; changing the product means a new insert.

Card inserts

Card inserts are folded paperboard dividers and cradles, sometimes printed.

Strengths

• Recyclable with the box in most paper streams.
• Can be printed, so the insert itself carries your brand or instructions.
• Light and economical, especially for sets with several items.

Trade-offs

• Less cushioning than foam for heavy or very fragile products.
• Complex shapes need clever folding, which is a structural design job.

Other options worth knowing

• Velvet or flocked inserts: EVA or card wrapped in fabric, ideal for jewellery and watches.
• Satin cushions: for single items such as watches, rings or perfume.
• Moulded pulp: pressed paper fibre trays shaped to your product. Plastic-free and protective, with tooling that suits larger runs.

Designing the insert

Whichever you choose, the insert is designed from the product itself. Send exact dimensions or, better, the product itself. Your 3D mockup and digital proof include the insert, so you can check the layout before production.

Compare options on our inserts page, or ask for structural design if your product needs something custom.

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