Bike Shipping Boxes

Custom Bike Shipping Boxes & Packaging

Our custom bike shipping boxes are engineered to meet the real-world demands of the bike industry—whether you’re shipping standard bikes, e-bikes, or individual components. Each box is built for a precise fit, ensuring maximum protection for frames, wheels, batteries, and accessories during transit. With streamlined assembly and space-saving storage, our packaging solutions help you ship smarter, reduce damage claims, and deliver a professional unboxing experience that reflects the quality of your brand.

Bike Boxes

Packaging & Inserts

Applications & Solutions

Services

Why Custom Bike Shipping Boxes Work for Your Brand

When you’re shipping bikes or e-bikes directly to customers, protection isn’t optional—it’s essential. Custom bike shipping boxes are built to fit your exact bike dimensions, parts, and accessories, reducing movement in transit and minimizing the risk of damage. This means fewer returns, less hassle, and a better customer experience from the moment the box arrives.

Beyond protection, custom packaging supports your operational goals. These boxes are designed for easy assembly, efficient palletization, and compact storage, helping you ship faster and more cost-effectively. Plus, with options for branding and sustainable materials, they allow you to make a strong first impression while aligning with your company’s values and image.

Custom Bike Shipping Boxes

We offer fully customizable bike shipping boxes with a range of sizes and styles—including Full Overlap (FOL), 2-piece, and 3-piece designs—built to protect everything from standard bikes to e-bikes, parts, and accessories. With options for material strength, structural design, and custom printing, you can create packaging that delivers both maximum protection and a memorable branded unboxing experience.

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Full Overlap (FOL) boxes are the most popular choice for bike shipping thanks to their exceptional strength and impact resistance. The top and bottom flaps completely overlap, creating multiple layers of protection that help safeguard bikes and e-bikes during transit. This design makes FOL boxes ideal for heavier loads and long-distance shipping, where durability is critical. Compared to 2-piece and 3-piece boxes, FOL boxes offer a simpler structure that’s easy to assemble while still delivering reliable protection—perfect for bike brands shipping directly to customers.

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2-piece boxes offer a versatile and professional packaging solution for bike brands looking to enhance both protection and presentation. Made up of a separate top and bottom, this style allows for a secure fit around the bike while also providing a clean, premium appearance. The 2-piece design makes it easier to load and unload bikes or e-bikes without compromising structural integrity. Compared to FOL boxes, 2-piece boxes provide a sleeker look and are often used when branding and unboxing experience are a priority, while still maintaining strong protection.

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3-piece boxes are designed for maximum flexibility and full coverage, making them ideal for shipping larger or more complex bike builds, including e-bikes with accessories. This style includes a base, a sleeve, and a cap, allowing the packaging to slide over the product and create a snug, reinforced enclosure. The 3-piece design offers enhanced structural support and is especially useful for heavier items or when extra protection is needed on all sides. Compared to FOL and 2-piece boxes, 3-piece boxes provide the most complete protection and are often used by bike brands that prioritize damage prevention and secure transport above all else.

Bike Packaging and Inserts

Our bike packaging products and inserts are designed to protect, organize, and elevate every shipment—whether you’re delivering standard bikes, e-bikes, or accessories. From durable outer boxes to custom foam and corrugated inserts, every solution is built to ensure your products arrive safely and leave a lasting impression.

Blister Packs

Blister packaging offers a clean, tamper-evident solution for displaying bike accessories, tools, and small parts in retail environments. The clear plastic front showcases your product while keeping it securely in place and protected from damage. It’s a professional, shelf-ready option that enhances visibility and deters theft.

Folding Cartons

Folding cartons are perfect for lightweight bike components, manuals, and smaller accessories that need compact, affordable protection. Ideal for both retail shelves and direct-to-consumer shipping, they provide a smooth surface for custom branding and a clean, polished look. Their slim profile makes them easy to store, stack, and ship efficiently.

Corrugated Mailers

Corrugated Mailer boxes are the go-to choice for bike brands shipping gear, parts, or apparel directly to customers. With sturdy construction and full customization options, they offer a premium unboxing experience while keeping contents protected in transit. Their self-locking design makes them easy to assemble and secure without the need for tape.

POP Displays

POP (Point-of-Purchase) displays are ideal for showcasing bikes, accessories, and branded merchandise in high-traffic retail spaces. We design custom floor displays that offer structural strength, product visibility, and brand impact—perfect for club stores, sporting goods retailers, and in-store promotions. Built for easy assembly and durability, our POP displays help you drive engagement and increase sell-through at the point of decision.

Counter Displays

Counter displays are a compact, high-impact solution for promoting smaller bike products like lights, tools, or safety gear at checkout. Designed to fit on retail counters and tabletops, these displays boost impulse purchases while reinforcing your branding. We offer custom shapes, inserts, and graphics to ensure your packaging gets noticed in tight spaces with limited real estate.

Poly Bags

Poly bags are a flexible, lightweight packaging option for bike apparel, soft goods, and small accessories. They’re great for cost-effective eCommerce shipping and can be customized with printed logos or warnings to maintain brand consistency. Use them as standalone packaging or as inner protection within a larger shipping box.

Corrugated Inserts

Corrugated inserts add structure and stability inside your box, keeping bikes, parts, and accessories neatly organized and protected during transit. They’re ideal for separating components like wheels, pedals, chargers, and manuals to prevent shifting or damage. Lightweight, cost-effective, and fully customizable, corrugated inserts improve both protection and the professional look of your packaging.

Foam Inserts

Foam inserts provide premium protection for delicate or high-value components such as e-bike batteries, displays, and sensitive hardware. Custom-cut to fit your exact product dimensions, they offer superior shock absorption and keep everything locked in place. Foam is often used by brands looking to minimize movement during transit and enhance the unboxing experience with a high-end feel.

Additional Packaging

POP displays showcase computer hardware and accessories at the point of sale, drawing attention to featured products or promotions. Designed to hold mice, headphones, or bundled items, they enhance in-store visibility and drive last-minute purchases. Fully customizable for branding and layout needs.

Bike Packaging Applications & Solutions

Applications
Solutions

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Bikes & E-Bikes

We design protective, custom-fit packaging for standard bikes and e-bikes, ensuring they arrive safely no matter the distance. From frame to battery, each component is secured using inserts, foam, or tailored structures to reduce movement and damage. Our boxes support efficient assembly, palletization, and branding to help your product make a strong first impression.

Helmets

We offer custom packaging for bike helmets that balances protection, branding, and shelf presence. Whether shipping DTC or for retail display, our cartons and inserts are designed to prevent scuffs, dents, and shifting. Pair with print-ready surfaces to promote your brand and product features effectively.

Batteries & Chargers

E-bike components like batteries and chargers require packaging that delivers both protection and compliance. We create snug, shock-absorbing inserts and boxes that reduce risk of damage and help manage lithium-ion shipping standards. Ideal for replacements or spare parts, our solutions keep high-value components safe and professional.

Bike Apparel

From jerseys to padded shorts, we provide clean, lightweight packaging for bike apparel that’s perfect for eCommerce fulfillment. Options include poly bags, mailer boxes, or branded folding cartons—each offering protection while showcasing your brand. Add printed elements for a retail-ready or premium DTC unboxing experience.

Pedals & Cranksets

We design custom inserts and protective boxes for pedals, cranksets, and drivetrain components, preventing scratches or breakage in transit. Our structural designs isolate metal-on-metal contact and keep hardware from shifting during shipment. These are ideal for kitted or individual part sales.

Wheels & Rims

Wheels and rims need packaging that holds their shape and prevents distortion, and our reinforced corrugated designs and inserts do just that. We help bike brands ship rims in bulk or as replacement parts without sacrificing protection. Add corner guards, foam, or partitions for extra reinforcement.

Handlebars & Stems

Handlebars, stems, and cockpit components are prone to damage if not properly secured—we offer packaging that keeps them locked in place. Whether included in a full bike box or sold separately, our designs reduce flex and eliminate movement. Options include custom inner supports and die-cut channels.

Brake Lights & Electronics

We package bike lights, GPS units, and electronic accessories with care, offering blister packs, folding cartons, or die-cut inserts for protection and visibility. These items often need a balance of security and retail display appeal. Our packaging enhances both, ensuring your tech products arrive intact and market-ready.

Tools & Repair Kits

From multi-tools to full kits, we build packaging for bike tools and maintenance accessories that keeps everything secure and organized. Our solutions include compartments, trays, and inserts to display and protect each item. Whether sold online or in stores, your kits stay complete and cleanly presented.

Locks & Security Devices

Bike locks and security gear benefit from tough, tamper-resistant packaging that shows off your product while keeping it secure. We offer blister packs, reinforced cartons, and custom boxes that highlight durability and function. Ideal for both retail and online fulfillment.

Accessories

From mirrors and bells to grips and racks, we offer tailored packaging solutions for all types of bike accessories. Whether you're shipping small items individually or bundling them with a larger product, we ensure each piece is protected, well-organized, and professionally presented. Our packaging helps prevent damage, reduce returns, and enhance the customer experience across both retail and eCommerce channels.

Additional Applications

If you have a unique product or specialized packaging need, our team is here to help. We’ve worked with a wide range of bike and e-bike brands to develop custom solutions for everything from complex kits to one-of-a-kind parts. Contact Brown Packaging to discuss how we can create packaging that fits your exact specifications and delivers real value to your business.

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Ecommerce

Your packaging is often your customer's first physical interaction with your brand—make it count. Our eCommerce packaging solutions are designed for efficient fulfillment, clean presentation, and a memorable unboxing experience. They’re tough enough for shipping and sharp enough to impress.

Retail Ready

We design retail-ready packaging that meets the display, stacking, and compliance standards of major retailers and bike shops. Our solutions help you meet visual merchandising goals while protecting your product in transit. Get to shelves faster, with packaging that performs from warehouse to storefront.

Durability & Protection

Your packaging needs to do more than look good—it must protect your bikes and components through rough handling and long-distance shipping. We design boxes and inserts to withstand impact, compression, and vibration, helping reduce damage claims and product loss. From rugged FOL boxes to custom

Supply Chain Optimization

Smart packaging design plays a major role in reducing shipping costs and improving fulfillment speed. We engineer your packaging for pallet efficiency, reduced dimensional weight, and easy packing, which adds up to real savings across your operation. Better design = better logistics.

Kitting & Assembly

We offer kitting and assembly solutions to help you deliver bundled parts, accessories, and documentation in a clean, organized format. Whether it’s a full bike setup or a maintenance kit, our packaging ensures everything is in the right place for a seamless customer experience. It saves time on your end and adds value on theirs.

Edge Crush Test (ECT)

The Edge Crush Test (ECT) measures how much pressure a corrugated box can withstand when stacked, making it essential for bike brands shipping heavy or bulky items. A higher ECT rating means the box can handle more vertical pressure without collapsing, helping prevent damage in warehousing and transit. We’ll help you choose the right ECT rating—such as 32, 44, or higher—based on your product weight, shipping method, and stacking needs.

Burst Rating

We test our corrugated packaging using the Mullen Test (burst strength) to ensure your boxes can handle high-pressure impacts during shipping. This test measures how much force the material can withstand before rupturing—critical for protecting heavy or high-value items like bikes and e-bikes. Ch

FSC® Certification

Show your commitment to sustainability with packaging materials that are FSC® certified, ensuring they come from responsibly managed forests. We offer FSC-compliant corrugated, chipboard, and paper-based products that meet environmental standards without compromising strength or performance. It’s a powerful way to align your packaging with your brand values and meet growing customer expectations for eco-conscious sourcing.

Brand Visibility & Custom Print

Turn your packaging into a marketing asset with high-quality print options that showcase your brand. Whether you're highlighting features, adding QR codes, or creating retail appeal, we help you build trust from the outside in. From subtle logos to full-color graphics, we match the look to your goals.

Modular & Scalable Packaging

As your product line grows, your packaging should keep up. We design modular and scalable solutions that can adapt to different bike models, accessories, or configurations using shared components. This helps lower tooling costs and simplifies inventory management.

Single, Double & Triple Wall

We offer single-wall, double-wall, and triple-wall corrugated materials to match your product’s weight, size, and shipping demands. Single wall is perfect for lighter accessories and apparel, while double wall is ideal for fully boxed bikes and e-bikes. For heavy-duty protection in bulk shipments or long-distance freight, triple wall adds the strength and rigidity needed to prevent punctures and collapse.

Flute Types

Choosing the right flute profile is key to balancing protection, print quality, and box thickness. We offer a range of options—B-flute for retail-ready packaging, C-flute for strong shipping boxes, and E-flute for thinner, high-resolution print applications. Each flute type affects cushioning, stacking strength, and presentation, so we tailor it to your packaging’s specific job.

Tamper Evident

Give your customers peace of mind with tamper-evident solutions that protect your brand’s reputation and reduce theft. From reinforced tape options to custom-sealed cartons and secure poly bags, we help you detect interference before it becomes a problem. Ideal for high-value items like e-bikes and electronics.

Additional Solutions

Have a packaging challenge that doesn’t fit into a standard category? We specialize in custom solutions tailored to unique products, shipping requirements, or branding goals across the bike and e-bike industry. Contact Brown Packaging to explore how we can help you create a packaging system that’s built around your product—and your customer’s experience.

Our Bike Packaging Services

Our bike packaging services are designed to help brands ship with confidence, combining protection, efficiency, and standout presentation. From custom boxes and inserts to structural design, printing, and prototyping, we deliver complete solutions tailored to your bikes, parts, and customer experience.

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Our structural design services are built around the unique challenges bike brands face when shipping products directly to customers. From bikes and e-bikes to small parts and accessories, we create packaging that offers precise protection, space efficiency, and ease of use. Every design is engineered to minimize damage, reduce shipping costs, and deliver a clean, branded presentation. We know your packaging isn’t just a box—it’s part of your product experience, and we design it to perform like one.

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Our graphic design services help bike brands create packaging that stands out and tells their story from the moment it arrives. Whether you need bold branding, retail-ready artwork, or clean, professional eCommerce presentation, we bring your vision to life with high-impact visuals. Every design is tailored to match your product, audience, and goals—helping you build recognition and trust. Great packaging doesn’t just protect—it connects, and our graphics make sure it leaves a lasting impression.

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Our print capabilities bring your bike packaging to life with professional, high-quality finishes tailored to your needs. We offer flexographic, digital, and lithographic printing, allowing you to choose the best option based on your packaging type, branding goals, and order volume. Whether you’re printing on corrugated boxes, mailers, or cartons, we ensure crisp visuals, accurate colors, and consistent results. From bold graphics to subtle details, our printing solutions help elevate your brand with every shipment.

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Our sampling and prototyping services let you test and refine your bike packaging before full production—so you can move forward with confidence. Whether it’s a custom box, insert, or branded design, we provide accurate, production-ready samples that reflect the final look, feel, and fit. This allows you to verify protection, assembly, and presentation, while making adjustments as needed. It’s a crucial step for ensuring your packaging meets both your product requirements and customer expectations.

Custom Bike Shipping Boxes & Packaging

Why Custom Bike Shipping Boxes Work for Your Brand

Custom Bike Shipping Boxes

Bike Packaging and Inserts

Bike Packaging Applications & Solutions

Our Bike Packaging Services

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