Power Bank Boxes.

A fitted insert holds the unit so its terminals cannot touch anything conductive. The cavity is cut to the device outline, which also stops it sliding about when the carton is dropped or stacked. The cable gets its own bay in the same insert, because a loose cable rubbing on the casing leaves scratches before the customer opens the lid.

We cut inserts from board for retail cartons and from E-flute where the pack ships direct.

Power banks are dense for their footprint, so the base has to carry more than the box dimensions suggest. A high-capacity unit in a carton the size of a deck of cards will push through a light tuck-end base on the first drop. We rate the board from the device weight, then add a weight-rated base where the count or the capacity justifies it.

Retail cartons run on folding boxboard, shippers on E-flute corrugated.

We plan defined compliance zones into the layout before the artwork is drawn. The panel carries room for the lithium battery marking and any certification text your carrier or forwarder asks for, sized so it stays legible at print. Confirm the marking requirement with them first, since it varies by transport mode.

We do not give dangerous goods advice, and we do not add compliance labels after a design is finished, so the zones need to be agreed at the start.

Full CMYK with the mAh figure as the largest element on the face is the usual retail spec. Capacity is the number shoppers compare, so it gets the most legible treatment and the brand sits behind it. Matte lamination hides fingerprints on a black carton and reads as a higher tier.

Soft-touch and foil detail on the logo are reserved for rigid board versions at the top of a range.

Common cartons run 4 by 3 by 1.2 inches for a pocket unit and 6 by 3.5 by 1.5 inches for a larger capacity bank. We measure the device with its cable and any case, then add insert wall thickness, so the outer size follows your unit rather than a stock list.

Send the device dimensions and weight together, because both drive the board choice.

The minimum is 500 cartons per size and artwork. Pricing steps down at each tier above 1,000, and the top of the range runs to 100,000 on the same tooling. The insert counts as part of the same order, so you are not placing a second minimum for it.

Production takes 7 to 10 business days after proof approval, or 5 to 7 business days on the rush schedule. A pre-production sample ships in 5 to 7 business days so the insert fit can be checked with your actual device before we run the job.

The sample fee comes off the invoice for the production order, and dieline work is done at no charge.

Only if the retail carton has to travel alone through a parcel network. A folding boxboard carton with a fitted insert is fine going out by the case to a store. For direct-to-customer orders we build the same footprint in E-flute corrugated, which takes the impact and keeps the print surface. Rigid board is the third option where the device is premium and the weight of the box is meant to match the weight of the product.