Two-piece rigid setup box with precision die-cut foam insert for electronics premium packaging — manufactured by Guangdong Bincai Color Printing Co., Ltd., a full-chain packaging enterprise with 22 years of experience (founded 2003). 18,000 sqm factory (10,000+8,000 smart factory) with KBA and Heidelberg presses. Daily output 1.7 million boxes.
Applications
Two-piece telescopic rigid boxes provide unmatched structural integrity for heavy or delicate items. The base and lid separate cleanly, revealing a perfectly fitted foam interior. Ideal for:
- Consumer Electronics: Wireless earbuds, smartwatches, fitness trackers, phone accessories, chargers
- Medical Devices: Diagnostic kits, surgical instruments, dental tools, hearing aids
- Industrial Components: Precision bearings, optical lenses, calibration tools, sensors
- Luxury Tech: Premium headphones, designer phone cases, limited-edition gadgets
- Promotional Kits: Branded USB drives, power banks, multi-item corporate welcome kits
- Audio Equipment: In-ear monitors, DAC/amplifiers, replacement ear tips
Customization Options
- Materials: 1500-2000 gsm greyboard (heavy-duty) wrapped in 200-300 gsm art paper, textured stock, or leatherette
- Foam Insert: EVA foam (40–80 Shore A hardness), cross-linked PE foam, PU memory foam; available in black, white, grey, or custom-matched colors
- Printing: Full-color CMYK offset on KBA 1050 4-color press; up to 7 colors + UV on Heidelberg 7+1
- Finishing: Gold/silver foil stamping, blind embossing/debossing, spot UV varnish, matte/gloss lamination, soft-touch coating, anti-scratch matte
- Insert Customization: Multi-cavity die-cut foam for multiple components, finger-pull cutouts for easy item removal, velvet/flocked surface lamination on foam
- Closure: Telescopic friction fit (standard), hidden magnetic flap, ribbon pull, or metal snap button
- Size: Custom dimensions up to 500×400×120mm for large-format devices
Production Specifications
- Press: KBA 1050 4-color offset + Heidelberg Speedmaster 7+1 UV
- Die-Cutting: Automatic Bobst-style die-cutting for outer box + CNC foam routing for inserts (±0.3mm precision)
- Foam Processing: CNC die-cutting, water-jet cutting, or die-press stamping depending on complexity
- Gluing: Automatic rigid box forming lines with reinforced corner construction for heavy loads
- Assembly: Hand-insertion of foam trays, accessory placement, protective film application
- Daily Capacity: 220,000+ rigid gift boxes per day
- Lead Time: 12–18 working days for new tooling (foam die); 8–12 days for repeat orders
- MOQ: 500–1000 units; trial orders accepted
Quality Assurance
- ISO 9001:2015 certified quality management system
- FSC Chain of Custody certified
- Foam QC: Shore hardness verified per batch; cavity fit tested with actual product samples
- Incoming Inspection: Greyboard thickness (±0.1mm), foam density (±5%), art paper GSM verified
- Inline QC: Color density every 500 sheets; glue bonding tested hourly
- Final Inspection: AQL 2.5 sampling; dimensional tolerance ±1.5mm; color delta E < 2.0
- Drop Testing: ISTA 1A and ISTA 2A simulated drop/vibration tests for protective packaging
- Free pre-production sample with foam insert (freight collect)
Factory
- 22 years of manufacturing excellence
- 18,000 sqm production facility (10,000+8,000 smart factory) in Foshan, Guangdong, China
- KBA 1050 4-color + Heidelberg 7+1 UV presses
- CNC foam cutting and die-cutting equipment
- Daily capacity: 1.7 million color boxes + 220,000+ gift boxes
- Export to 40+ countries across Europe, North America, Middle East, and Southeast Asia
FAQ
Q: Can you design the foam insert based on my product dimensions?
A: Absolutely. Send us your product’s 3D CAD file (STEP/IGES), a 2D dimension drawing, or a physical sample, and our engineers will design a precision-fit foam cavity with appropriate clearances (typically 0.5–1.0mm tolerance).
Q: What foam densities are available for different protection levels?
A: EVA foam ranges from 40 Shore A (soft, for lightweight consumer items) to 80 Shore A (firm, for heavy industrial components). Cross-linked PE foam offers superior rebound for repeated use. We’ll recommend based on your product weight and drop-test requirements.
Q: Can the foam insert hold multiple components with different shapes?
A: Yes. CNC routing creates multi-cavity layouts with different depths for each component. We can include finger-pull recesses, accessory compartments, and cable-management channels.
Q: Is the telescopic lid easy to open but secure during shipping?
A: Our telescopic fit is precision-engineered with 0.5–1.0mm clearance between lid interior and base exterior. Combined with shrink-wrap or a branded belly band, the box stays securely closed during transit while remaining easy to open for the end user.
