Custom Hat Boxes

Updated 2026-10-06

Custom hat boxes are printed boxes sized to protect the crown and brim of a hat, used by milliners, cap brands, western wear shops and boutiques for retail, gifting and shipping. Options include round two-piece rigid boxes, square boxes, corrugated shipping boxes, carry handles and crown inserts. Send your hat dimensions, quantity and artwork, and a specialist replies with pricing.

Protects crown and brim
Round or square styles
Carry handles available
Shipping-ready builds

Get a free quote in minutes

Size, quantity and email. We reply with pricing and options.

Ships to the USA and CanadaNo obligation

Protecting a hat's shape, in store and in transit

A hat can lose its shape from a single crushed corner in a parcel. Custom hat boxes are sized around the widest point of the brim and the height of the crown, so the hat sits in the box without pressure on either. Many hats also benefit from a crown support insert, which holds the hat in place and stops the brim resting on the base of the box during transit.

Round two-piece rigid boxes, made from chipboard wrapped in printed paper, are the classic choice for fedoras, wide-brim and occasion hats, and a cord or ribbon handle turns them into a keepsake. Square rigid boxes suit caps and beanies. Custom hat boxes for shipping use corrugated board, either as a branded mailer or as an outer carton around a retail box. Matte paper wraps, foil logos and embossing suit milliners and premium labels.

Keep the lid design bold, because a round lid is seen from above on shelves and in photos. Repeat the logo on the side band. Personalized hat boxes for weddings, races and gifts can carry names or dates as separate versions. For cap brands with many designs, one box size with a printed label or sticker for each style keeps stock simple.

Popular uses

Fedoras and occasion hats
Wide-brim and sun hats
Western and cowboy hats
Fitted and snapback caps
Milliner and couture pieces
Wedding and racing event gifts

Specifications

Size	Made to your exact inside dimensions (L × W × H)
Materials	Paperboard (SBS), kraft, corrugated (E, B or double wall), rigid chipboard
Printing	Full colour CMYK, Pantone (PMS) spot colours, inside and outside printing
Finishes	Matte, gloss or soft-touch lamination, spot UV, foil stamping, embossing, debossing
Add-ons	Window cut-outs, inserts, handles, custom tissue paper and stickers
Proof	Digital proof on your dieline before production

Request pricing for custom hat boxes

Make it yours

Options for custom hat boxes

Box shapes

Round two-piece hat boxes for brimmed hats, square and rectangular boxes for caps and beanies, each sized to the hat's brim and crown.

Rigid builds

Chipboard wrapped in printed or textured paper for retail and gift hat boxes that hold their shape and can be kept and reused.

Shipping builds

Corrugated hat boxes and outer cartons that protect brims in transit, printed with your logo or kept plain to protect retail boxes inside.

Handles

Cord, ribbon or rope handles on round boxes, so the hat box can be carried out of the store or kept for travel and storage.

Crown inserts

Paperboard or foam crown supports that hold the hat in position and stop the brim pressing against the box base during shipping.

Finishes

Matte or gloss paper wraps, soft-touch lamination, foil stamping and embossing on lids and side bands for milliners and premium labels.

How it works

Ordering custom hat boxes

Get a free quote

Request a quote
Tell us the box style, size, quantity and where it ships.
Get pricing and a proof
A specialist confirms options and sends a digital proof of your design.
Approve and print
Nothing goes to press until you approve the proof.
Delivered to your door
Boxes ship to your address in the USA or Canada.

FAQ

Custom Hat Boxes: questions answered

Still unsure? Ask a packaging specialist.

What size hat box do I need?

Measure the widest point of the brim and the height of the crown, then allow a little room on each side. Send those measurements, and we size the box so the hat sits freely without pressing against the walls or lid.

Can custom hat boxes be used for shipping?

Yes. Corrugated hat boxes ship on their own, and rigid retail hat boxes can go inside a plain outer carton for protection. A crown insert helps keep brimmed hats from shifting in transit and protects the brim's shape.

Are round hat boxes available with a logo?

Yes. Round two-piece hat boxes can be wrapped in printed paper with your logo on the lid and side band, or finished with foil stamping on a plain colored wrap. The digital proof shows the layout.

Do you make personalized hat boxes for gifts?

Yes. Names, dates or messages can be printed as separate versions for weddings, horse races, birthdays and gifts. Send the list and quantities, and each version appears on its own digital proof before production, so names can be checked.

How do I get pricing for custom hat boxes wholesale?

Send the hat dimensions, box shape, material, handles, inserts, quantity and artwork through the quote form. A specialist replies with pricing and a suggested build for your hats, and you approve a digital proof before production.

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