1
Single Host
cavity, and a groove for the cable
- Holds
- The mod, seated in a lined bed
- Ships
- Formed
- Not for
- A kit that arrives with a tank, a spare cell or a card
Vape pen mod packaging
Custom Vape Pen Mod Packaging: 3-Layer Protection & TPD Readiness
Mitigate shipping damage and transit friction with die-cut dense foam inserts, rigid box structures, and reliable 3–5 day sampling. Each part sits in a cut-out of its own, so nothing shifts in transit.
Kit classes
Three Kit Classes, Three Trays
A kit box is defined by how many cavities its tray has, because that is the detail a brand cannot change later without a new die. Add an accessory and the tray is redrawn.
2
Host and Tank
cells, side by side
- Holds
- Host in the first cell, the tank standing in the second
- Ships
- Formed
- Not for
- A full set with a battery and a charging cable
3–4
Full Kit
a seat for each, and room for the card
- Holds
- All four parts, each in its own cell
- Ships
- Formed
- Not for
- A light folding carton — a heavy kit goes in a rigid box
Three layers
Three Layers Between the Mod and the Doorstep
The headline names three layers, and they stack. A fault in any of them shows up as a mark on the device rather than the box, and each is drawn before the artwork is.
- 01
Rigid shell
Wrapped greyboard, 1.5 to 2.5 mm, with the corners turned rather than cut. This is the layer that holds the lid square when a heavy mod sits inside it for a month in a warehouse.
- 02
Die-cut insert
Dense flocked EVA or pulp, cut on the same file as the box. The cavity is what stops the mod moving, so the lid closes on the tray rather than on the device.
- 03
Flocked face
A soft flock on the insert and the lid liner. The screen and the paint rest on fibre rather than board, and a reprint arrives with the finish signed on the sample.
Send the Kit, Get the Tray
Three measurements — the mod, the tank, the battery or cable — are enough to begin. The quote is then built on the cavity count that comes back.
Cavity by cavity
What Each Cavity Has to Do
Four parts, four jobs. Reading across, the left is the piece that goes in and the right is the clearance the tray owes it — the lines that get drawn before anything is printed.
- 01Mod
Seated with the fire button in relief and the charge port reachable. A snug cell that presses the switch drains the battery before the box is opened.
- 02Tank
Its own cell, standing clear of the host. A tank resting on a mod carries the weight of both, and glass that takes a knock on a shelf arrives cracked.
- 03Battery
Isolated in a lined cell, terminals clear of any metal. A loose cell that bridges a contact in transit is the fault a retailer will not forgive twice.
- 04Cable and card
A shallow bed cut to the folded cable beside them, and the lid closes flush instead of riding up on the accessories.
Structures
Four Rigid Structures
Three of the four hold a tray, and the fourth does not. Which structure you get is set by how heavy the kit is and the way the box should open, not by the budget.
01
Lid and base
Its base is wrapped and its lid separate, which makes it the strongest of the four. The board thickens for the heaviest kit without changing how the box looks.
Heavy mods · retail sets
02
Magnetic book
The lid swings open on a hinge and holds shut on two magnets. It lifts clear of the tray sitting in the base.
Single host · gifting
03
Drawer
Slide the tray out of its sleeve on a ribbon or a finger pull. The kit is presented in the tray instead of lifted out of it.
Starter kits · full kits
04
Folding carton
Folding board, printed and machine-glued, is the plainest of the four. Only for a light host with no tray — a heavy kit will not survive the fold in transit.
Light host onlyWeight and freight
Weight, Freight and the Flat-Pack Rule
Weight is what separates a kit box from a pen box: it decides the board, the way the box ships and what the pallet costs.
- Carry
The lid has to carry the mod
A box mod is dead weight in a thin board. The lid is specified against the weight of the kit, and the corners stay square after a stack, not only after the first sample.
- Formed / flat
Formed for kits, flat for the rest
Rigid boxes with a built-in tray ship formed and loaded, because the tray is what sets the walls. Only the folding carton with no tray — a light host — travels flat.
- Right-sized
Drawn to the kit, cheaper on the reprint
The cavity is drawn to the parts rather than to a stock size. A box closer to the kit weighs less and stands smaller on a pallet, and the same file holds that saving run after run.
How it runs
Six Steps, One Tray
Six steps, and the first three are yours to measure. A change to the size of any part after step four is a new tray rather than an edit, which is why the count is settled first.
- 01
Send the three sizes
The mod, the tank and the battery or cable, measured or in the post. Those three set the cavities on the tray.
- 02
Count the cells
Whether the tray seats a part or four, the count is settled before the artwork, because it decides the die.
- 03
Pick the tray
Flocked EVA for a soft-touch seat, or moulded pulp for a large recycled run. A die per cavity count.
- 04
Draw the dieline
A single file cuts the tray and the shell, and the first dieline reaches you inside 24 hours.
- 05
Approve a sample
First a white dummy in 3 to 5 days to pack the real kit, then a printed dummy in 7 to 10 days to fix the color.
- 06
Run the batch
Once the dummy is signed, the line runs the batch and the file is kept for the next order.
Customer voices
What Buyers Say After the First Run
Our first run came back with the mods loose in the tray. The cavity had been cut 1.8 mm too deep, and the body sat low and rattled under the lid. We sent the measurement back, and the second die held the mod the way the sample had.
Reorders go in on the file we signed. 6 colorways have run on the same tray without a new tool, and that is why the same kit keeps coming back to the same supplier.
What we check first is the lid. A stack of 40 boxes in the warehouse has to keep its corner, and the board specified for the weight of the mod has held that shape all winter.
The tray is cut around the fire button and the charge port, with 3 mm of relief over the switch. The mod drops in, the port lines up, and our packing line noticed it on the first run without being told.
We launched with 5 kits, and each sat in a cavity drawn for its own parts, because a host alone and a full set with a spare cell need different boxes.
Freight is the number I watch. Keeping each cavity tight to the kit cut roughly 25 % off the carton volume we used to send, and the damage claims we were logging have stopped.
FAQ
Straight Answers, Before You Order
What is the smallest run you will take?
500 units. A mixed order of a lid-and-base box and a drawer counts against the same 500, so a first run can test two structures at once.
How long does the whole order take?
Four to six weeks from the signed printed dummy, covering printing, die-cutting and gluing. The window is quoted with the sample rather than after the order.
Can the tray be cut without the physical device?
Yes, from a drawing with the mod, tank and battery dimensions plus the button and port positions. A white dummy then proves the fit, and the first printed tray is cut only once that dummy packs the real kit.
Do you arrange a test report on the structure?
Yes, on request, and it travels with the sample. The structure is drawn first, then put through the test the report covers, so a buyer reads the result rather than a claim.
Who supplies the artwork, and how is the color fixed?
You supply the words and the logo, and every panel is drawn here to the size your market prints at. A Pantone chip sets the color, and the proof is signed before the printed dummy is cut.
Start here
Keep the Dieline, Reprint the Kit
The file stays on our shelf, so the tenth run of a kit arrives with the cavity, the clearance over the button and the color unchanged.