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EVF72061

Hexagonal Double-Wall Perimeter Insert

Available in a wide range of custom configurations & material selection.
Order 1 sample. Or order 100K+ units. Or anything in between.
Affordable delivery across North America.
Design support, warehousing, testing, assembly available.
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Product details

Top highlights

Requires a hexagonal outer box
Creates a hollow perimeter buffer
Manual assembly for all six inner walls

About this product

This folding carton insert fits inside a hexagonal outer box to create a thick, hollow buffer wall around the perimeter. By folding inward and dropping to the floor of the outer container, the insert forms a clean, double-wall presentation that hides raw edges and centers the product.

Delivered as a flat-folded tube, the insert pops open into a hexagon before the six inner walls are manually folded and interlocked. This insert provides excellent lateral crush resistance and a premium unboxing experience, though it requires dedicated hand assembly for each unit.

Common uses

Premium cosmetics
Specialty confections
Fragile retail items
High-end electronics

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Size and quantity

Detailed dimensions

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What do your dimensions describe?

Hexagon width (point to point)

Insert height

Perimeter wall thickness

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Materials and print

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Premium Retail and Fragile Goods Presentation

Premium Cosmetics and Fragrances

The double-wall insert creates a thick, high-end frame around central bottles or jars, elevating the perceived value while keeping the product strictly centered.

Specialty Confections and Foods

Provides a clean barrier that prevents delicate items from shifting against the outer walls during transit, while offering a pristine interior presentation.

Fragile Glassware and Ceramics

The hollow perimeter acts as a lateral crush buffer, keeping delicate hexagonal or round vessels safely away from the outer impact zones.

High-End Electronics and Wearables

Creates a precise, clean inner void that hides raw board edges, matching the unboxing expectations for premium tech accessories.

Kitting and Fulfillment Operations

Hand-Packed Retail Rollouts

Because all six buffer walls must be folded and interlocked by hand, this insert is best suited for premium product lines where the presentation value justifies the slower packing rhythm.

Limited Edition Promotional Kits

When launching a special campaign, the thick perimeter walls provide a substantial, high-value feel without requiring custom vacuum-formed plastics.

Subscription Box Programs

For recurring deliveries that use a signature hexagonal outer box, this insert can be adjusted month-to-month to fit different featured items while maintaining a consistent unboxing experience.

When to Consider Simpler Inserts

High-Speed Packing Lines

If fulfillment speed is the primary concern, a simple die-cut flat pad or a pre-assembled vacuum-formed tray may be a better choice than a multi-fold paperboard insert.

Simple Void Fill Needs

When the goal is purely to stop movement rather than create a premium presentation, standard crinkle paper or a basic folded collar may be more practical than folding six interlocking walls.

Board Caliper and Assembly Labor

Board Thickness and Tab Fit

The side tuck tongues that lock the inner walls together are highly sensitive to material thickness. Standard folding carton board yields crisp folds and secure locks, while thicker corrugated flutes can cause the tabs to bind.

Print Surface Planning

Both the top ledge and the inner walls are fully visible to the consumer. Depending on the artwork, the board may need a double-sided coating to ensure a consistent finish across all visible surfaces.

Outer Box Compatibility

This insert relies entirely on the outer hexagonal box for its final shape and stability. The internal dimensions of the outer box must exactly match the outer footprint of the insert.

Assembly Labor Budget

While the insert ships flat and pops open easily, folding and locking all six inner walls is a manual process. This labor time should be factored into the overall fulfillment plan.

Buffer Width and Inner Wall Adjustments

Buffer Wall Width

The width of the top ledge can be expanded or reduced to change the thickness of the hollow perimeter, allowing the same outer box to accommodate different product sizes.

Inner Wall Height

The template automatically adjusts the inner wall height based on the specified board thickness, ensuring the foot flaps rest perfectly flat against the floor of the outer box.

Bevel Angle Adjustments

While designed for a regular 60-degree hexagon, the corner angles can be modified to fit irregular hexagonal outer boxes, though this requires careful testing of the interlocking tabs.

Packing details

Flat Shipping and Storage

The insert is glued along a single side seam by the converter and delivered flat. It pops open into a hexagon immediately before the inner walls are folded.

Additional notes

Corner Interlock Clearance

The 120-degree corners rely on precise tab insertion. If you change the board grade after initial prototyping, the tab clearances must be re-tested to ensure they still lock smoothly.

FAQs

Does this insert require glue or tape during packing?

No. The side seam is glued by the manufacturer before delivery. During fulfillment, the six inner walls fold down and interlock using side tuck tongues, requiring no additional adhesive.

Can this insert be erected automatically?

No. While the flat tube can be popped open easily, folding and interlocking the six individual buffer walls is a manual process.

Can I use this insert without an outer box?

No. This is strictly an internal component designed to rest against the walls and floor of a rigid or folding hexagonal outer container.

Will this design work with corrugated board?

It is generally not recommended. The small interlocking tabs at the corners are designed for the crisp folding behavior of paperboard. Thicker corrugated flutes often cause these tabs to bind or tear.

Which panels are visible after assembly?

Once folded, the top horizontal ledge and the vertical inner walls are fully visible. The outer walls and the bottom foot flaps are hidden against the outer box.

How is the insert delivered?

It ships flat as a side-glued tube. At the packing station, the operator pops it open into a hexagon before folding the inner walls down.

Can the width of the hollow wall be changed?

Yes, the top ledge width can be adjusted to create a thicker or thinner buffer. This allows you to use the same outer box for different product sizes.

Does the insert attach to the outer box?

No, it relies on a friction fit against the inner walls of the outer hexagonal box and does not require adhesive to stay in place.