How about EVA liners? EVA (high-density): high rigidity and precise moulding, suitable for ‘securing’ products — jewellery, watches and small electrical appliances; drawbacks: high cost and expensive moulding fees. When selecting EVA, the guiding principle is ‘snugly securing irregularly shaped items’.
How about moulded pulp? Moulded pulp (environmentally friendly): biodegradable, dyeable and with a customisable structure; suitable for gift boxes with an ‘eco-friendly selling point’ — such as wine bottle inserts and electronic device inserts; drawbacks: high minimum order quantities and average precision. When selecting moulded pulp, prioritise ‘environmental claims that add value’.
The economics of cushioning inserts: EVA excels in tiered presentation, expanded polystyrene in cost-effectiveness, and pulp moulding in environmental friendliness — once you’ve clearly defined ‘what needs protecting and what the gift value is’, you’ll ensure your money is well spent on the inserts.
First, clarify what needs protecting. The role of the insert: stabilisation (preventing product displacement), cushioning (absorbing impact), and presentation (creating a tiered effect upon opening). First, distinguish between items that are ‘vulnerable to impact’ (glass, ceramics) and those that are ‘vulnerable to compression’ (electronics, precision components) before deciding on a solution — use high-density materials for impact-sensitive items, and materials with good resilience for compression-sensitive items.
How about expanded polystyrene (EPE) inner liners? EPE: lightweight, good resilience, inexpensive, suitable for ‘wrapping’ products — glass bottles, cosmetics; Drawbacks: limited visual layering and prone to deformation. When selecting EPE, prioritise ‘cost-effectiveness for bulk packaging’.
The ‘stability’ experienced upon opening the box comes half from the box design and half from the inner lining — if the cushioning lining is chosen incorrectly, even the finest box cannot protect its contents. This article clearly explains the selection of inner linings; clients commissioning bespoke gift boxes may refer to it as required.
Combinations and prototyping? Common combinations: EVA inner tray + expanded polystyrene base; pulp tray + flocked surface (flocking on the outer layer enhances the premium feel). Once materials have been selected, produce a prototype (for test assembly and drop tests) before placing an order. When prototyping, ensure the product ‘fits inside, can be removed easily, and won’t break when dropped’.
