A headphone box is a carton, often with a shaped or moulded insert, built specifically around the wider, non-uniform shape of over-ear or on-ear headphones rather than a generic rectangular fit. The headband and ear cups create an irregular footprint that needs careful internal design.
Why Headphone Shape Is a Genuine Packaging Challenge
Unlike earphones, over-ear headphones do not fold into a simple flat shape, which means the box needs either a shaped internal cavity or a fold-flat headphone design accounted for in the insert. We design the internal layout around your specific model.
Styles We Make
We build tuck end and window boxes with a moulded pulp or foam insert shaped to your headphone's profile.
Materials
Coated folding carton board is standard for the outer box, with moulded pulp or foam providing the shaped internal fit.
Order Sizes We Support
Custom headphone boxes are available from around 100 to 250 units, suiting audio brands.
Average Headphone Box Prices
As a general guide, headphone boxes typically cost between £0.40 and £1.40 per unit, depending on size, insert complexity, material and finish.
Sustainability
Recyclable folding carton board and moulded pulp inserts are available as a plastic-free alternative to foam packaging.
Getting Started
Send us your headphone's dimensions, folded and unfolded if applicable, and we will design a suitable shaped insert. We build a proof before production and UK-wide delivery.
