Structural Design Services for Custom Box Inserts

Our Kansas City team consists of leading experts in structural design. They specialize in creating product inserts that are both aesthetically beautiful and structurally sound. Common box inserts include jars, bottles, tinctures, canisters, and other products.

Due to the completely custom nature of every insert project we require a deposit of $250 to begin this service.


    "The boxes we had made by Box Genie turned out better than we could have imagined. Perfect for our products and loved by our customers."

    Zach F.
    Owner & Founder, Oak & Iron

    "The pricing is competitive and fair, but seriously it's the quality that makes all the difference, especially if your products require attention to detail. We highly recommend Box Genie for your packaging needs. "

    Sabrina L.
    Founder & Owner, Tuyo

    "The product boxes came out great with a nice tough finish to them. I will be using Box Genie from now on."

    David P.
    Owner, Bond Creek Knives

    "Excellent product! Quick production and great customer service."

    Andrew G.
    VP, BreakerOne9

    "My boxes are beautiful! I'm about to order some more boxes. I would recommend this company."

    Donna M.
    Norvanna Beauty

    "Awesome. The art guys were helpful making sure design was centered properly and sent a proof before printing. 👌"

    Scott N.
    Zombyz Toy Box


    This natural brown corrugated cardboard is what most of us think of first when we imagine a box. This material provides an eco-conscious feel that holds dark colors well and provides a simple and modest aesthetic for any package. Kraft material also has the highest recycled content of any material making it the most eco-friendly.

    Essential White

    Our essential white corrugated cardboard material is a cost-effective classic for custom branded box creation. This standard white board with a low shine offers a dependable canvas for showcasing any colors, logos, text or design elements.

    Magic White with High Definition Print

    For a box that’s clearly built to impress, select Magic White for your material and let our HD printers do the rest. This premium corrugated cardboard feels smooth to the touch, looks lusciously glossy and provides photo-quality prints you never thought possible on subscription boxes or custom packaging.

    Box Measurements: All measurements are done from the inside.

    Mailer Material is E flute corrugated cardboard.

    Printing Options

    Make your custom packaging look great from every angle with our two-sided four-color printing option. Or you can also keep things simple with one-sided four-color printing.

    If you have your own design files ready to print, just open the design tools to download a die-line template matched to box type and size and upload to begin. BoxGenie will review our order, reach out with any questions, and quickly get your custom packaging printed.

    And you can always use our online design tools to choose patterns, colors and fonts that work for your brand. Our 3D tools let you see every angle down to the dust flaps and corners.

    Please note that your choice of material greatly impacts your color vibrancy and printing precision. For darker colors over a natural brown, choose Kraft. To get a full spectrum of colors that pop, choose Essential White. For photo-quality images and the most premium look and feel, Magic White material gives you the HDPrint quality you need.

    You may cover your box with as many colors or designs as you like, all for the same cost.

    We use the highest quality corrugated cardboard.

    Best Practices & Help

    Here are a few tips from our design and product teams on designing your box:

    • Always convert to CMYK before uploading files as this allows tighter control over your colors and images.
    • All text should be at least 8-point in size and use bold colors made up of no more than one or two inks (C, M, Y or K).
    • Choose your custom size based on interior measurements.
    • Include at least a 0.25-inch bleed when graphics extend past die-line.
    • Lines in a solid or dark color should be no thinner than 1 point.
    • Download our templates here if you prefer to create your own box design from scratch.

    We use the highest quality corrugated cardboard.

    Remember, durable custom mailer boxes are great for so many different types of manufacturer shipments including: packaging samples and packaging sample packs, retail promotions, cosmetics and cosmetic samples, cosmetic sample packaging, sample sizes, sample containers, sample packets, makeup, beverages, vitamins, capsules, tablets, spices, nutritional products and supplements, skin care products, creams, lotions, gels,glass containers, small jars, vials, lids and all sorts of items in full size and travel sizes.

    We're here to help you every step of the way with your specific customer specifications, from design through checkout. We do everything in-house, from our own facility to ensure the highest quality packaging. Sign up and take a look at our newsletter for great, flexible packaging ideas that could be a big hit for your specific product.

    High Quality & Fast Delivery


    Two-Sided Printing

    Printed In-House

    Real Reviews From Real Customers

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    Deliver the highest quality possible with High Definition Print

    Never before has there been a faster and more cost effective way to get high-definition designs on your printed mail and packaging. Simply select Magic White for your custom printed material and let our HD printers do the rest.

    • Picture perfect: Take your packaging graphics to the next level with tiny targeted ink dots designed for crisp imagery and text
    • Fast and precise colors: It takes just a single pass of the printer to bring any color combinations, gradients or hues to life with no swapping print plates to slow it all down
    • Luxe feel with a glossy finish: Our Magic White premium board feels smooth to the touch and provides the perfect canvas for your photo-quality graphics
    Learn more about packaging in our blog

    FAQs - Custom Mailer Boxes