When it comes to board game inserts, cardboard is one of the most popular material choices. As we discussed in our guide to inserts, cardboard is cost-effective, easy to manufacture and can be produced in many different forms.
However, not all cardboard is the same. As a publisher, if you opt to use a cardboard insert for your game, you’ll face a decision between using regular cardboard and corrugated cardboard.
Regular cardboard and corrugated cardboard have several major differences in their durability, cost and shipping weight. They also look and feel a little different, meaning they may affect the way players perceive your game.
Below, we’ve explained the differences between these two types of cardboard for board game inserts, as well as when you may want to consider one over the other for your game.
Need help choosing the right materials for your game? Contact us and we can help you select materials that match your vision and manufacturing budget so you can get your game ready to manufacture as soon as possible.
What is Regular Cardboard?
Regular cardboard, or paperboard, is a single-layer material that’s produced from compressed paper fibers. It’s the same material that’s used for board game boxes and it’s a common choice for game inserts.
In board games, regular cardboard is typically used for simple inserts, dividers, and lightweight trays. It can be cut into a variety of shapes, die-cut for precision and then printed on directly for a clean finish.
Regular cardboard has several advantages. It’s lightweight, has a smooth finish, is affordable to use in game manufacturing, is recyclable, and is easy to cut and print.
However, it also has some weaknesses. When regular cardboard is placed under heavy load, it can warp and tear. This means it may run into durability issues for games with lots of large and heavy pieces.
What is Corrugated Cardboard?
Corrugated cardboard is made of three layers. There are two flat layers that make up the outer layers of the cardboard, with a fluted sheet of cardboard between them.
This multi-layer structure gives corrugated cardboard extra strength and cushioning. When you look at a shipping box, which is designed for durability, you’ll usually see corrugated cardboard used to make it.
Corrugated cardboard is less common as an insert material than regular cardboard. However, it offers several advantages. Because of its structure, it’s more durable and less likely to warp due to weight or heavy use.
This makes it great for holding heavy pieces such as miniatures, or for games that may be used by young children who may not be the most careful when handling game components.
The downsides of corrugated cardboard are that it’s bulkier than regular cardboard, heavier due to its structure, and has a less refined look and feel. Because of its extra mass, games that use corrugated cardboard may be slightly more expensive to ship.
Regular and corrugated cardboard also have different costs. Our guide to cardboard costs for board games goes into more detail about how type, thickness and other factors can affect the costs of boxes, inserts and other cardboard components for your game.
When to Choose Regular vs. Corrugated
Like with other game materials and components, there’s no one-size-fits-all rule that you should follow when choosing between regular and corrugated cardboard for your game’s inserts.
However, there are a few best practices that are worth following. In general, regular cardboard is a solid choice for games that only have light, simple components, such as basic card games and light board games with relatively few wooden or heavy plastic pieces.
Regular cardboard is also a good choice for casual games that may not be played very heavily or often, as these games are usually exposed to less lifetime wear and tear.
Due to its lower costs and lighter weight, regular cardboard is also a good choice if you want to keep manufacturing and shipping costs for your game as low as possible.
On the other hand, corrugated cardboard offers extra strength and durability that’s important for some games. If your game insert needs to hold large and/or heavy miniatures, using corrugated cardboard is a good idea, as it’s less likely to warp or bend under their weight.
If you’re making a collector’s edition of your game, corrugated cardboard can also give it a more rugged feel. Finally, if you’re worried about your game’s insert and components being damaged during shipping, corrugated cardboard can give some extra peace of mind.
The Bottom Line on Regular vs. Corrugated Cardboard for Inserts
Like with your other game components, your choice of regular or corrugated cardboard for your game’s insert will have an impact on its durability, its look and feel, as well as its manufacturing and shipping costs.
If your game is lightweight, designed for occasional casual play, or has small components that don’t need much physical support, regular cardboard offers cost advantages that can make it a good choice for you.
On the other hand, if you’re making a heavy board game with lots of miniatures or other pieces that need to be supported and stored safely, the extra ruggedness of corrugated cardboard may be worth considering.
As always, we’re happy to help you compare and choose materials for your game. Feel free to contact us if you’d like help with your game’s inserts or any other aspects of manufacturing and our team will assist you to make the best decisions for your game.
