- Material: XPE foam, IXPE foam
- Expansion ratio: 25 times (40 kg/m³), 30 times (33 kg/m³)
- Thickness: surface layer 2–5 mm, bottom layer 20–40 mm (thickness can be customized)
- Colour: black + red, black + blue (colour can be customized)
- Flame retardant grade: UL94 HF-1
Customization
Made to order: density, thickness, colour and shape to your drawing. Die-cutting, CNC routing, lamination to film or fabric, slitting and adhesive coating all run in-house, so the part we quote is a finished part, not just a sheet. How a custom part is cut and routed explains what to send with the drawing.
Regular material: MOQ 1,000 m², lead time 15–20 days from order confirmation. Custom parts are quoted from the drawing. A4 samples are free, shipping included.
Opening a gift box is the moment the product is judged, and the insert is what the customer sees first. A gift box foam insert holds the item exactly where the design intends and gives the tray a finished, deliberate look. Bofeng builds these as a two-layer construction — a thin coloured surface layer over a thicker base — so the cavities cut cleanly and the presentation reads as considered rather than improvised.
Features
- Two-layer build – a thin coloured surface layer over a 20–40 mm base, so the tray looks finished and holds firm.
- Shaped cavities – cut to the item, so it sits exactly where the packaging design places it.
- Cushioning – absorbs the handling a gift box sees between packing, shipping and opening.
- Presentation finish – smooth cut edges in black with red or blue as standard.
- Low added weight – adds presence to the pack without adding weight to it.
- Custom thickness and density – 25× (40 kg/m³) and 30× (33 kg/m³) grades.
Applications
- Premium retail packaging – electronics, cosmetics and spirits presented in a fitted tray.
- Corporate gifts – branded sets held in position for presentation.
- Jewellery and small valuables – soft cavities that hold items without marking them.
- Seasonal and limited editions – presentation trays produced for a single campaign.
- Subscription and hamper boxes – compartments that keep mixed contents arranged.
Specifications for gift box packaging foam
A gift box foam insert is a die-cut part, so the sheet has to hold a cavity, keep its thickness and cut cleanly.
| Foam | Expansion | Apparent density | Single-layer thickness | Why this grade |
|---|---|---|---|---|
| XPE | 10–20× | 50–100 kg/m³ | 3–15 mm (heat-bonded 15–200 mm) | Use this XPE range as a starting point for the display layer. Approve colour, cut edges and removal feel on the presentation sample. Verify layer alignment and retention after testing the complete packed box. |
| IXPE | 20–30× | 33.3–50 kg/m³ | 0.1–15 mm | Fine-cell sheet for the lid liner and for thin interleaving between parts, where a firmer sheet would not close. |
Base material specifications are on the XPE, IXPE and IXPP material pages; finished products are on the XPE foam and IXPE foam pages. Tell us the load, the space available and the service temperature and we will confirm the grade against your drawing.
Why Choose Bofeng Foam
- Two-layer construction: thin surface layer over a 20–40 mm base.
- Flame-retardant grade available – UL94 HF-1.
- Black + red or black + blue as standard, further combinations on request.
- Die-cut to your layout from a drawing or a physical sample.
- Samples and specification sheets available before production.
Cavity depth, retained bottom and the surface the customer will see are worked through in our custom foam insert design guide.
Two-Layer Gift Inserts: Specify the Display Layer and the Supporting Base
Assign a Job to Each Layer
Identify the visible top, the load-carrying base and the bond between them. Colour contrast and surface finish belong to the presentation, while pocket geometry and remaining bottom define support. Record the material of each layer; one average density does not describe a mixed construction.
Review Pocket Levels and Closure
A set containing different product heights may need different cavity depths or support elevations. Check the closed box with the actual items so a lid does not concentrate load on the tallest product. Trial finger access and removal without tearing the visible top layer or lifting its bond.
Check the Visible Bond and Finish
Inspect the perimeter and pocket walls for open bonds, adhesive residue, debris and inconsistent alignment. Use a representative sample of the complete insert rather than separate colour swatches. If the facing or glue changes, review appearance and compatibility again even when the foam dimensions remain unchanged.
Keep Display and Distribution Decisions Separate
An approved presentation sample does not automatically validate the shipping pack. Define whether the insert is for display, protected shipping or both, and agree the applicable tests. Retain the box, product revisions, layer stack and sample as the reference for repeat orders.
For sample identity, dimensions and the acceptance record, use the first-article review checklist with the application-specific checks above.
Approve the Empty and Loaded View
Photograph the approved insert both empty and with the complete gift set so a later packing review can distinguish an appearance change from a changed support location.
Conclusion & Inquiry
Packaging foam covers the wider range of custom inserts and trays, and cosmetic packaging foam applies the same presentation approach to beauty products. Contact us with your box dimensions and item layout for a cut proposal.
