Custom TENS Massager Boxes

Inserts for TENS Massager Boxes

We design the insert around your exact contents. The unit sits in a cut-out sized to its shape. Pad packets lie flat in a shallow well. Lead wires are coiled and tucked into a channel or a small compartment. The charger and cable have their own space. If there is a manual, it can sit under the insert or in a slot in the lid.

Card inserts printed in a matching colour are neat and cost-effective. Foam inserts offer extra protection for more expensive units, especially those posted on their own. Moulded pulp inserts are another option for brands that prefer a paper-based tray.

If you sell refill pads separately, consider a smaller matching box or pouch for them. Customers then recognise your refills easily when they reorder. Brands that sell a massage oil or gel alongside the unit often match the carton to their bottle cartons for massage oils so the two sit together on a pharmacy shelf.

• Unit cut-outs sized to the device
• Flat wells for pad packets
• Lead wire channels
• Compartments for chargers and clips

Printing Clear Product Information

People buying a TENS machine are often in pain and want reassurance. The box should make the basics clear: what the device is for, how many modes or programmes it has, what is in the box and how it is powered. A simple diagram of pad placement can help, though detailed medical guidance belongs in the manual.

Health devices often carry regulatory markings, warnings and contraindications, such as advice for people with pacemakers or during pregnancy. You must supply the correct wording and markings for your device; we print exactly what you provide and do not check regulatory content. Leave enough space on the side or back panel so this information is legible.

Calm, clean designs work well for this category. Soft blues, greens and whites suggest care and wellbeing, while a bold colour can suit sports recovery and EMS brands. Product photography against a plain background looks professional and trustworthy. Pharmacy own-label ranges tend to follow the layout conventions of their tube cartons for scar gels and creams: claims on the front, directions on the back, warnings on a side panel.

Sizing the Box to the Kit

Lay out every item as you would like it in the box and measure the overall footprint and the height of the tallest item, often the unit or the charger plug. We add room for the insert and the board. A compact box is better for postage and shelf space, so we try to arrange items efficiently without crowding them.

If you have several kits, such as a basic set and a deluxe set with extra pads, a shared outer size with different inserts can keep printing simple. The insert changes, while the outer box stays the same with a different label or print panel.

Remember to allow for the manual and any warranty card, which can be thicker than expected once folded. A manual that is forced in under a tight insert lifts it and makes the lid sit badly. Measure the folded manual and tell us whether it should go underneath the insert or in a pocket in the lid. Our walkthrough on measuring a product for a fitted box covers the allowances we add for inserts.

Pharmacy, Clinic and Online Sales

Pharmacies often stock TENS units on shelves or hang them on display hooks, so a hang tab is useful. Physiotherapy clinics may sell or lend units to patients, and they appreciate a sturdy box that can be returned and reused. Online, the box should either be strong enough to post on its own or packed inside a shipping carton.

For maternity TENS units, which are often hired or bought for a short period, a box that closes securely and stores everything neatly is particularly valued. Clear labelling of the contents helps when the unit is returned or passed on.

Sports recovery and EMS brands often sell through gyms and online marketplaces, where photos of the box matter as much as the box itself. A clean, bold design with a clear product photo on the front looks strong in thumbnail images and helps your listing read clearly among similar devices. Clinic suppliers often buy from the wider health and wellbeing packaging range so that the whole shelf shares one board and finish.

List Every Item in the Kit Before Asking for a Box

The box for a TENS unit is really a box for its insert, so start with an inventory rather than a size. Write down each item with its measurements: the unit, the number of lead wires, how many pad packets and their folded size, the charger or batteries, the manual folded as it will ship, and any carry pouch. Note which items are heavy or scratch easily. From that list we draw the insert first and the carton around it, which is the reverse of how most packaging is sized and the reason the kit arrives tidy. If you sell pads on their own, the small carton style used for chargers suits a refill pack.

Have your regulatory wording ready as text rather than a picture, so it can be set at the size the rules require. Email the inventory, box style and artwork and a custom quote arrives within one working day, then a free design proof showing the insert layout. Boxes are produced in 4 to 7 working days after approval and reach UK mainland addresses free and tracked in 2 to 3 days. Misprinted or crushed cartons reported within 10 days are reprinted or refunded.