Hat packaging is a custom box, mailer or hat box sized to a specific hat style, so the crown and brim arrive undented and the hat looks right on a shelf or at the door. TBPB makes it to your hat’s measurements with no minimum order, and our price-beat guarantee applies if you bring a written quote for the same specs.
Crown, brim and what gets crushed
A hat is awkward because it is round, it has a stiff brim, and a crown that holds shape only until something leans on it. Baseball caps and snapbacks arrive with a curved or flat bill that must not bend. Beanies are soft and forgiving, so they ship in a slim flat box. Bucket hats fold flat without damage, while wide-brim hats and fedoras need a real hat box with room for the brim and the crown. Decide which of those you sell, because it sets the box type before anything else does.
Measuring a hat for a box
Measure the hat as it will sit in the box, not from the label. For a cap, record the width across the bill, the length from the back strap to the tip of the bill, and the crown height. Add about 1/8 inch of clearance per side for a snug fit. A cap standing on its crown needs height for the crown plus a small margin so the lid does not push down. A flat-packed beanie only needs the folded footprint. If the hat has a pom or a tall peak, tell us. Send us one sample and we can measure it for you.
Mailer, folding carton or rigid box
For ecommerce, a corrugated mailer lets the hat travel without a shipping carton around it. Folding carton paperboard is lighter and takes fine print, so it suits retail shelves and gift orders. A rigid box feels like a gift but takes more room to ship, so we recommend it for premium launches and wide-brim hats. Printing and finishing options include:
- Full-color CMYK print or a Pantone match for a brand color
- Matte aqueous coating, or soft-touch lamination for a velvet feel
- Foil stamping or embossing on the logo
- A die-cut paperboard insert or crown support to hold shape
- A window or hang tab for retail display
When another style fits better
If the hat ships alongside other apparel, a mailer box may hold the whole order. For stores, look at retail display boxes and corporate gift boxes for merch drops, or browse the custom retail packaging range. Send the hat dimensions, or a sample, and a quantity, even if it is one, and we draw the dieline and quote it.
Frequently asked questions
Is there a minimum order for custom hat packaging?
No. TBPB has no minimum order. You can order one box to fit a sample hat or thousands for a merch launch. Send the hat measurements or a sample, with a quantity, and we draw the dieline.
How do I measure a hat for a box?
Measure the hat as it sits in the box: bill width, length from back strap to bill tip, and crown height. Add about 1/8 inch per side. For beanies, just measure the folded footprint. Or send a sample hat.
Which box suits a baseball cap?
For shipping, a corrugated mailer with a crown support works well. For retail, a folding carton with a window or hang tab. Either way, make sure the bill is not bent and the lid does not press the crown.
Can a box protect a wide-brim hat?
Yes, but it needs a real hat box with room for the brim, usually round or large rectangular. Rigid boxes work well for premium hats. Tell us the brim width and crown height and we advise on structure.
Can the box be printed inside and out?
Yes. Inside-and-out print is available in full color or Pantone match, with matte, gloss, soft-touch, foil or embossing options. The inside lid is a good place for a brand message or care instructions.
Do you match another supplier’s quote?
If you send a written quote for the same size, board, print and quantity, we will beat it.
More Custom Retail Packaging
See the full Custom Retail Packaging range, or explore related options with no minimum order and our best-price guarantee:
