Corrugated shipping boxes / JETDIELINE

Insert pad

Flat insert pad as a base, intermediate layer or top insert in a box. Flat dimensions follow the box's inside space; side clearance makes the pad smaller. An optional grid forms identical rounded cutouts.

Shipping Electronics

Template ID: corrugated.insert.pad
Construction: Corrugated shipping boxes
Current template version: V1
Dieline preview version: V1

How the shape is constructed

Flat corrugated board pad as a base, intermediate layer or top insert in a box, optionally with a grid of identical rounded cutouts; dimensions = box inside length × inside width.

How it is assembled

Separate the pad from the sheet, remove the cutouts and lay it flat in the box – as a base, between two layers or at the top beneath the lid.

Material and grain direction

Flute direction parallel to the pad's longer side: greater bending stiffness across the larger span (check with a test printer).

Test fit, folding and closure on a sample made from the intended material. Confirm material thickness, grain direction and production steps with your printer.

Dimensions of the illustrated example

300 × 200 mm

30 × 20 cm11.81 × 7.87 in / ″

Width: 300 mmHeight: 200 mm

Inside dimension

These dimensions describe the preview, not a fixed packaging size. The app recalculates the dieline for your own dimensions.

What to consider for this construction

Clearance to box wall

Clearance between pad edge and box wall on each side; the pad is smaller than the flat dimensions by twice the clearance.

Cutouts

Enable or disable the grid of identical cutouts in the pad.

Cutouts side by side

Number of cutouts along the pad width, evenly distributed.

Cutouts in rows

Number of cutouts along the pad height, evenly distributed.

Cutout width

Width of each cutout; a bridge of at least 10 mm remains between cutouts and at least 5 mm to the edge.

Frequently asked questions

Why does 300 × 200 mm produce a smaller pad?

padClearance is subtracted on both sides in each direction. The starting value of 1 mm turns 300 × 200 mm into a pad of 298 × 198 mm. Here, flat dimensions refer to the intended box inside space. Actual clearance can only be confirmed with the box and target material.

Are cutouts enabled in the starting values?

Yes. cutouts is enabled; the starting profile contains two cutouts side by side and one row. Each cutout is 100 × 60 mm with a 5 mm radius. Disable the grid if you need a solid intermediate layer. The area metric and cut length then change accordingly.

Can I mix different cutout sizes?

The template generates a grid of identical cutouts with shared width, height and radius. Different individual contours are not a parameter of this V1. Columns and rows control distribution. For a product-specific contour, you need another suitable construction or a separately checked reference dieline.