Headphone packaging has to protect a product with an unusual shape. An open-ear headset may have a curved band, compact transducers and a charging cable or other accessories in the same box. The insert needs to keep each component in place, make the contents easy to identify and let customers remove the product without wrestling with the package.
As SHOKZ’s packaging supplier, HTAECO developed molded-pulp packaging around those practical requirements. SHOKZ’s OpenRun Pro 2 product page confirms the box includes the headset, carrying case, USB-C charging cable and printed materials. SHOKZ also states that it uses 100% recyclable paper pulp for product packaging. A 2025 MUSE Design Awards entry for the OpenRun Pro 2 packaging describes a design using sugarcane and bamboo pulp for the outer box and recycled pulp supports. The award entry credits Shenzhen Shokz Co., Ltd. as entrant and client.
The insert should support the headset at suitable contact points, limit movement in transit and separate smaller items so they do not rub against the main product. Cable placement and the carrying case should be considered at the same time as the headset cavity. This helps the layout feel intentional and avoids adding a second tray simply to solve an accessory-fit problem later.
The package should also be easy to open and repack during sampling. A balanced design leaves enough clearance for removal while holding the product firmly during handling. Fit checks with production-representative samples can reveal pressure points, loose areas and assembly issues before a design is released.
A successful design must work through more than the unboxing moment. The package’s intended shipping configuration, handling conditions and production volume all inform material thickness, geometry and tooling. Sample review and agreed packaging tests help teams evaluate whether the product stays positioned and whether the insert can be made consistently at scale.
HTAECO offers molded-pulp packaging for mobile accessories and develops custom structures from product requirements. Learn more about how molded pulp absorbs and manages impact and our customization process. For a headset project, share the product CAD or samples, accessory list, box dimensions and shipping route through our contact page.
The goal is a package that keeps the headset and accessories organized, protects them in distribution and reflects the product’s design language with a practical fiber-based structure.
