Custom Molded Fiber Charger Packaging Insert

Inserts that pin the charger down

The charger is almost always the heaviest single item in a device box, and it is almost always the item the tray handles least well, because the design effort goes into the device cavity beside it.

The consequence is predictable: the charger moves, meets the device, and the device arrives marked. In a carton that is stacked or dropped flat, the charger becomes a blunt object travelling at speed toward the display.

We design the charger pocket as the primary cavity, not the leftover space:

• Deeper pockets than the device cavity, so the charger sits below the tray face and its mass is carried by the tray floor.
• Thicker surrounding walls where the charger sits, sized from the unit's weight rather than the tray average.
• Prong-safe geometry for pin and folding-prong plugs, so the prongs cannot act as a lever against the wall.
• Cable channel from the charger pocket to the device, letting the cable be dressed before the lid goes on.

Where the pack is a retail box that ships direct, we will usually recommend a full-depth charger pocket with a rib behind it, because the courier journey is where a heavier pocket fails.

MOQ 10,000 pieces per design; tooling 7–15 days, production 15–25 days after sample approval. Weigh the charger on its own before briefing us - that number drives the whole layout. Or see the electronics packaging range.