Packaging used to hold and ship consumer products may include a packaging insert having an exterior profile that substantially matches an interior profile of the box it is placed in during assembly. In some embodiments, the packaging insert may be formed using a thermo-forming process that inhibits the formation of defects, such as stress marks, located near or on the corners of the packaging insert. The packaging insert may include a side wall having a plurality of extended portions and a plurality of abbreviated portions. In some embodiments, the packaging insert may include a plurality of flaps rotatably connected to a body of the packaging insert.