Custom Printed Hair Dryer Boxes with Fitted Inserts

The body is L-shaped, the cable is two metres of loose weight and the nozzles are small enough to get lost. Loose in a box, all of it bangs about in transit.

A hair dryer box solves that with a die-cut card insert. The dryer body sits in a shaped cut-out, the cable coils into its own well and each nozzle has a pocket. Nothing moves, so nothing scratches.

The outer box is then free to do the selling. The front shows the dryer at close to life size, the side lists the wattage and the attachments, and the back carries the directions and the safety text.

The product inside might be a 2,000 W salon unit or a 800 g travel model folded in half.

It sits in our hair care packaging range with the cartons for sprays and bars that often share a shelf with it.

• Salon brands retailing a professional dryer at the front desk
• Hair electrical start-ups selling online through their own site
• Hairdressing wholesalers packing own-label dryers for trade
• Travel dryer brands selling through gift and luggage shops
• Blow-dry kit sellers bundling a dryer, round brush and section clips
• Marketplace sellers who need a box that photographs well

A folding travel dryer closes to about 180 x 140 mm, while a salon dryer with the nozzle off is about 230 x 200 mm and 80 mm thick at the motor.

Then add the attachments. Two concentrator nozzles side by side need about 80 x 70 mm of insert space, and a diffuser can be 120 mm across on its own. A coiled cable wants a well about 90 mm wide.

Lay everything out on a sheet of paper, draw a rectangle round it with 10 mm of margin and that is your insert size. The box adds about 5 mm on each side for the walls. Our page on UK cosmetic box sizes covers the general method for measuring up.

A flat card divider leaves the dryer free to slide, while a well cut to the shape of the body holds it with no padding.

We cut inserts from card and, as an option, foam. Card is cheaper and prints well; foam cushions a heavy motor better on a unit above a kilogram. Inserts are made on request and the quote lists the one we suggest.

A full colour photo of the dryer at near life size tells the shopper what is inside without opening the box. Coloured dryers in pink, red or blue look strong against a plain background.

Print the attachments on a side panel as small line images with a count beside each: one dryer, one brush, four clips. Buyers scan that list before anything else.

The back panel takes the technical text. Wattage, cable length, voltage and the care notes all go there in a size that can be read at arm's length.

It ships flat, squares up quickly and takes a gloss full colour print well.

A rigid lid and base box suits a premium dryer, a salon-grade unit or a gift kit. The greyboard walls carry the weight, the lid lifts off in one piece and the box is kept rather than binned.

Both styles take an insert. The folding carton needs a heavier board than a cosmetic carton would, so the walls do not bow under a motor. Board, rigid and finish options are available on request. Our guide to box styles and closures shows how each one opens.

It makes the dryer colour pop and it wipes clean on a salon shelf.

Soft touch lamination with a foil logo suits a compact dryer sold as a gift. The box feels like the lid of a phone box and the foil picks out the brand name without a busy front.

Spot UV over the dryer image and matt everywhere else is a middle ground many hair brands pick. It is covered in our print finishes guide and costs less than full foil.

That weight lands on one corner when a parcel is dropped.

An auto-lock base takes the load better than a tuck. For online orders, the printed box goes inside a plain outer so the print arrives clean, and the insert stops the dryer shifting inside.

Rigid lid and base boxes travel assembled. They need a tight outer or a tissue wrap so the lid does not lift in transit. Both are available on request.

1. Square up the carton and press the auto-lock base flat.
2. Drop the card insert in with the cable well toward the hinge side.
3. Coil the cable into its well and clip the plug into the slot.
4. Seat the dryer body in its cut-out and press the nozzles into their pockets.
5. Lay the instruction leaflet on top, close the lid and tuck the flap.

A two metre cable coiled takes a space the size of a saucer.

The second is choosing standard cosmetic board for a salon dryer. A 400 gsm carton bows on a 280 mm wall with a kilogram inside, so we suggest a heavier board or a rigid box for those.

The third is printing the dryer photo at low resolution. A 300 mm front panel shows every pixel, so send the product image at full size. If it is not sharp enough, our designers tell you on the proof. Kit boxes with brushes and clips follow the same rules as our cosmetic gift boxes for beauty sets.

A photo of the dryer with its parts laid out helps us plan the insert.

You get a free design proof showing the front, sides, back and insert before we cut anything. Quantities are quoted per order, from £0.25 per unit, with the written quote giving the figure for your size, board and insert.

Production runs 4–6 business days after approval, and delivery is free and tracked to UK addresses in 2–3 business days. Report a misprint or transit damage with photos inside 10 days and we reprint or refund that part of the run. Our Design Your Packaging page shows how to send your logo for the proof.