Can You Add Inserts in Vape Cartridge Boxes? Complete Packaging Guide
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Can We Put Inserts In The Vape Cartridge Boxes?

date read icon March 19, 2026

Vape products have become a product that is seen in almost every smoke shop and dispensaries across the United States. The packaging demand is also growing with more brands entering the market. But with that demand, one major concern is also raised, which is the safety of the product. Packaging plays a significant role in protecting the fragile vape products while presenting them professionally. 

Vape cartridges are small and considered the most fragile part of the vape, which is made with glass components. Glass makes them vulnerable to leaks, scratches, and breakage, especially during shipping and handling. That’s why businesses need packaging that keeps them secure and stable during transit. 

“According to research by Grand View Research, the US e-cigarette and vape market was valued at USD 8.98 billion in 2022 and is expected to grow with a CAGR of 29.8% from 2023 to 2030.”

As you can see, the demand for vape products is increasing, and brands are searching for smart packaging solutions that not only keep the product safe but also maximize the customer unboxing experience. This is where the vape cartridge box inserts do their magic. 

You must be wondering how it's actually possible. Well, these inserts perfectly fit inside cape cartridges boxes. They are designed to hold each branded cartridge securely in place. Inserts are used to reduce movement and improve overall packaging protection. Stay tuned to learn how inserts improve vape cartridges and ensure product integrity. 

What Are Vape Cartridge Box Inserts?

vape-cartridge-box-inserts

You must be wondering, what are inserts in packaging? Vape cartridge box inserts are basically known as specialized internal compartments that prevent product movement inside the box. They are typically made of cardboard, foam, or plastic and help prevent product damage during shipping. They are designed to fit perfectly into a small slot or holder that keeps products intact. 

It is important to understand that the inserts for vape cartridge boxes act as a strong protective support system. As we have already discussed, these vape cartridges are made of glass chambers, which increases the risk of damage during shipping and handling. Vape packaging inserts help solve this problem by holding them securely in their place. Custom inserts help enhance overall product presentation and buyer experience. 

Why Brands Use Custom Inserts in Vape Cartridges Packaging?

custom-inserts-for-vape-packaging

When a customer buys a vape cartridge, they expect the product to arrive safely. If a customer receives their order and finds a loose cartridge rolling inside the box, eventually getting damaged will ruin the brand reputation in seconds. These carts are small and made using glass, thus they need extra care and protection during storage and transportation. This is where vape cartridge box inserts come in handy. Let’s discuss why brands look for quality custom insert packaging for cartridges: 

Keep Products Safe During Transit

Custom inserts help keep products safe by providing a precise and secure fit for delicate vape products. These inserts are designed to make sure vape cartridges remain stable. Since vape cartridges contain fragile glass chambers that are filled with oil, even the smallest cracks can cause the product to leak. By preventing movement within the packaging, help minimizes the risk of bumping related damage. There are inserts for vape cartridge pouches, which tend to distinguish from those used in cartridge boxes, primarily due to the rigidity and space available in the packaging. The whole purpose is to protect them against the inclement conditions during transit.

Improve Product Presentation

Packaging plays a vital role in enhancing products perceived value. Vape packaging inserts help keep cartridges neatly arranged inside the box. This improves product presentation and help brand present their delicate products in a more organized way. Custom vape cartridge inserts help creates premium unboxing experience. 

Build Brand Credibility

Custom printed vape cartridge box helps build brand credibility. When the product arrives safely and looks professional, it builds trust among customers. It enhances brand perceptions. It may look like a small packaging detail, but it can make a big difference for growing vape businesses. 

Types of Inserts Used in Vape Cartridge Boxes

Different types of vape box inserts are made using various packaging materials. In the USA, different vape brands have different packaging demands based on their budget, packaging style, and protection requirements. The right insert can make a huge difference in keeping the product secure. 

We can already guess that you must be excited to know more about the different types of vape inserts. Let’s cut to the chase and discuss the primary types of inserts used in vape cartridge packaging:

  • Foam Inserts 

  • Cardboard Inserts 

  • Plastic or Blister Inserts

  • Eco-Friendly Inserts

These are some of the most common types of vape cartridge box inserts. Let’s discuss them in detail:

1. Foam Inserts

foam-inserts-packaging

Foam inserts are considered one of the most common insert types. Brands highly prefer them for a vape cartridge. Foam inserts for vape cartridges offer great cushioning and protection against shock or sudden jerks. They are considered an ideal choice for premium packaging. Brands can choose from EVA foam, polyurethane foam, and custom-cut inserts. 

2. Cardboard Inserts

custom-foam-inserts

Brands these days choose cardboard inserts for vape boxes because it offers superior product protection. It helps prevent product damage and leakage. Cardboard inserts are considered a versatile choice and help improve customers’ unboxing experience. They are lightweight, fully customizable, and a sustainable choice used to keep glass cartridges safe during transit. 

3. Plastic or Blister Inserts

plastic-inserts-packaging

Plastic inserts are usually used to display multiple cartridges. Brands can add a transparent plastic insert, which is often thermoformed to hold the cartridge in a secure way. 

4. Eco-Friendly Inserts

eco-friendly-packaging-inserts

Brands that prioritize sustainability choose eco friendly inserts for cartridge boxes. They help reduce environmental impact and help build a positive brand image. Choosing custom inserts made from recycled paper or pulp improves customer experience, making them a popular choice in modern packaging.  These inserts are best suited for vape and gummy packaging requirements to establish product safety. 

We’ve added a table below, which helps you decide which insert type is an ideal option for you:

Insert Material

Protection Level

Sustainability

Cost

Best Use Case

Foam Inserts

High

Low

Medium

Premium vape cartridge packaging

Cardboard Inserts

Medium

High

Low

Eco-friendly packaging

Plastic Blister Inserts

Medium

Low

Low

Retail display packaging

Eco Friendly Inserts

Medium

High

Medium

Sustainable vape packaging

How Custom Vape Cartridge Box Inserts Help With Branding

branded-packaging-inserts

Cartridge packaging with a custom insert also offers an excellent opportunity for branding. It helps brands build a strong identity in the market. When a customer sees how neatly the product looks inside the custom printed vape cartridge box, it immediately communicates professionalism. These inserts support and improve the overall look of the packaging. 

One of the best things about these inserts is that they can easily be made to match the exact size requirements. Some of the most common vape cartridge sizes include:

  • 0.5 ml cartridges: This is the most common size for smaller cartridges. It is mostly used for premium or high concentration oils. 

  • 1 ml cartridges: This is the most used size for vape cartridges in the market. Brands can easily customize the insert size to prevent shifting during shipping. 

The key is to design a perfect size that matches cartridge sizes. 

How to Design an Effective Vape Cartridge Box Insert

vape-cartridge-box-insert-design

The vape cartridge market is growing; therefore, brands need to design packaging that actually works for their business. 

“According to Future Market Report, the global vape cartridge market is estimated to grow to $15.25 billion by 2032, with a growing CAGR of 10.2%.”

This growth rate makes it even more important for brands to design an effective cartridge packaging with custom inserts. Brands need to make sure that the size is accurate. That’s because if the insert is too loose, the cartridge will have a higher chance of getting damage during transportation. If it’s too tight, it will be hard for customers to remove the cartridge. The insert size should be a mix of both. We have the best CBD packaging boxes tailored to your pre-requisites so your products reach safely.

Another important factor is to choose the right material for vape cartridge box inserts. Brands can choose among cardboard, foam, plastic, or molded based on their packaging goals. 

The next thing brands can do is to use branded colors or add a logo to the vape packaging itself. Brands can add QR code verification. That way, customers will easily be able to scan them and verify product authenticity. Effective vape packaging design ideas will make your product appear even more appealing to customers. 

Final Verdicts

After reading all this, you shouldn’t be asking questions like whether you can actually put inserts in the vape cartridge boxes. Instead, you should be making sure that you are getting the perfect size for your delicate products. Vape cartridges require reliable packaging for maximum safety. That is why vape cartridge box inserts are considered an essential part of modern packaging. These inserts might look small, but they play a huge role in keeping the packaging perfectly organized and visually appealing to buyers. 

Vape cartridges are no less than precious jewels. The vape industry is projected to grow over time; therefore, brands need to pay more attention to packaging quality. A vape box with improved security and presentation helps create an unforgettable unboxing experience and build trust among customers. 

Reach out to Print247 today to design custom insert packaging for cartridges that ensure product safety and help strengthen brand identity. With high quality materials and flexible customization options, Print247 helps vape brands maintain a professional appearance in today’s competitive market. 

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AUTHOR
Bill ‘Hogg’ Ryan

Bill is a Houston-based packaging writer with 6 years in the industry. His hands-on career began with printing machines; he has built profound expertise in custom packaging solutions across multiple sectors, including cosmetics, food, and retail. A recognized industry contributor in the State. Bill now shares insights through writing, focusing on packaging trends and innovations. In his leisure time, he can be seen riding his favorite Stallion, ‘Tex,’ or jamming to country music.