Industry

Protective packaging & industrial.

Not every packaging challenge fits neatly into a product category. Many of the most interesting honeycomb applications sit at the intersection of multiple operations — a die-cut insert that also fan-folds, a cookie-cut pad array that doubles as a containment tray, a custom fitment that replaces three separate foam components with a single honeycomb piece.

How it works

In-carton containment.

One of the fastest-growing applications for custom honeycomb is in-carton containment — using precision-cut pads and inserts to hold a product securely in position within its outer corrugated shipping case, without the need for foam, moulded pulp, or thermoformed trays.

A set of honeycomb pads, cookie-cut or die-cut to the product’s profile, are placed around or beneath the product inside the carton. The pads prevent the product from moving in any direction during transit — absorbing impact, preventing part-to-part contact, and maintaining product position through the full distribution chain.

Real examples from Axxon’s production: small pads securing infant car seats in their shipping cartons; custom pads containing plastic planters within corrugated shipping cases. Two very different products, solved with the same fundamental approach.

Why it works

Six reasons this combination wins.

  • Foam replacement

    Equivalent or superior protective performance to EPS/EPE foam, with full recyclability at end of life.

  • Multi-operation flexibility

    Cookie-cut + die-cut + fan-fold combinations solve complex containment problems with a single material.

  • Custom geometry

    Pads engineered to the specific profile of the product — full-contact support, no over-cushioning.

  • Clean unbox experience

    No foam residue at the consumer's end. Recyclable in standard curbside streams.

  • Consultation-first

    Our team will review your packaging design and recommend the appropriate operation, cell size, and panel spec.

  • Prototype validation

    Samples produced for fit-and-function validation before production commitment.

Products we supply

3 products. One complete package.
Hands separating two cookie-cut paper honeycomb pieces by hand, with no tools required

Cookie-Cut Pad Arrays

Multiple identical pads nested in a single panel and separated by hand at the point of pack-out. Operators peel pads from the panel and place them in the carton without tools.
  • Fast, clean, consistent
  • No tool required at pack-out
  • Reduces panel waste
See Specs
Die-cut paper honeycomb frame with a rectangular window cut through the panel in a single press stroke

Custom Die-Cut Inserts

Shaped inserts engineered to the exact geometry of the product. For complex profiles or high-volume production where consistency is critical.
  • Steel rule die
  • High-volume ready
  • Replaces foam fitments
See Specs
Long paper honeycomb panel bent along a reverse slit score into a peaked ridge

Fan-Fold Void Fill

Fan-folded panels deployed as continuous void fill within cartons and shipping cases. Fills irregular spaces and prevents product movement.
  • Ships flat
  • Deploys on demand
  • No pre-formed tooling
See Specs

Need an application-specific honeycomb solution?

Bring the foam fitment. We'll explore the alternative.

Talk to us your current foam fitment, the product it protects, and your annual volume. We’ll explore a honeycomb equivalent and help you with fit-and-function validation before you commit to a production order.

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