Custom Power Bank Boxes

Inserts That Hold Everything in Place

A power bank is dense and heavy for its size, and it usually ships with a cable, sometimes a plug adapter and a short leaflet. Without an insert, all of these knock against each other and against the box walls in transit, which can scuff a glossy finish and dent the corners of the carton.

A folded card insert with a cut-out for the bank and a small compartment for the cable is the simplest and most cost-effective fix. For premium models, a moulded pulp or foam insert gives a tighter, more protective fit. Magnetic wireless banks benefit from a shallow cradle that keeps the charging face up, so the first thing a customer sees when they open the box is the product, not a coiled cable.

Send us the bank's dimensions with any accessories and we will lay out the insert on your free proof.

Getting the Dimensions Right

Measure the power bank at its longest, widest and thickest points, including any protruding buttons or a built-in stand. Then measure the coiled cable and any accessories. The internal box size is set by the insert, not just the bank, so share everything that needs to go inside.

Slim pocket power banks often fit a box around 110 x 75 x 25 mm, while high-capacity models with displays may need closer to 170 x 90 x 35 mm. Magnetic banks for phones are usually squarer. If you sell several capacities in the same design family, it can be more efficient to use one box size with different inserts than to make a new box for each model.

Allow a little extra length if you include a printed manual folded on top of the insert. Our guide on how to measure a bank with its cable explains how much the coil adds.

Print and Finish for Tech Accessories

Tech packaging tends to look sharpest with a clean palette: white or black board, one accent colour and crisp photography of the product. Full colour CMYK print handles product shots well, and a spot colour keeps your brand accent consistent across a range. Matt lamination gives a modern, smudge-resistant surface, while spot gloss over a product photo makes the device look polished and glassy.

Silver or holographic foil on the capacity figure is an effective way to make that key number jump out. Embossing the logo adds a tactile detail that customers notice when picking the box up.

Consider the unboxing too. Printing the inside of the lid with a short charging guide or a line such as 'charge me fully before first use' answers the most common customer question before it reaches your support inbox. A coloured insert in your accent shade makes the product pop when the lid comes off, and costs very little compared with printing the whole inside of the box. These details matter more than ever for brands selling online, where the box is the first physical contact a customer has with you.

If you sell on marketplaces, remember that your box will be photographed against a white background. Strong colour or a dark box helps the listing image get noticed among competitors. You can see matt lamination and spot gloss compared in our finish guide.

Information to Plan For

Power banks carry more mandatory and expected information than most accessories. Leave room for electrical ratings, battery chemistry, the waste electrical equipment symbol, your company name and address, model number, barcode and any markings your compliance adviser specifies. We do not advise on regulations, but we can lay out a clear information panel so nothing is squeezed in at the last minute.

Many brands print one master box and add a small label for model-specific details such as colour or capacity. That is especially useful if you sell the same bank in several colours.

A short QR code linking to your manual or warranty registration saves space and lets you update instructions without reprinting. Markings that differ by market can go on compliance labels on the base rather than in the print.

Lead With the Capacity and Measure the Bank With Its Cable

Power bank boxes are bought on numbers, so decide the front panel first: the capacity in mAh, the fast-charge or wireless feature and a clear product image, with the logo smaller than you might expect. Then measure the bank with its cable coiled and any adapter bagged, because the insert has to hold the heavy bank still and keep the cable from pressing on it. Say whether the box hangs on a peg, stands on a shelf or ships in a mailer, and whether several capacities share one outer with a model label. Corporate gifts usually move to a two-piece rigid box with a foam insert and a printed sleeve carrying the client's logo.

Email the dimensions, the contents, the format and the number of models or colours, and a custom quote comes by email within one working day, often with a suggested insert layout. The free proof shows the dieline and the specification panel. Production takes 4 to 7 working days after approval, boxes arrive by tracked courier to UK mainland addresses, and misprinted or damaged boxes reported within 10 days are reprinted or refunded.