Custom Printed Baseball Cap Packaging

Packaging That Makes Your Brand Look Sharp

Perfect for apparel brands, merch stores, eCommerce retailers, and promotional kits, our cap packaging is built to match your fit—from delivery to display.

Materials That Hold Shape & Style

We use durable, premium materials that prevent crushing and creasing while showing off your branding front and center.

• Rigid chipboard – Ideal for retail and high-end cap lines
• Corrugated E-flute or B-flute board – Strong yet lightweight for shipping and storage
• White SBS or kraft board – Smooth for crisp printing or eco-conscious branding
• Optional soft-touch, matte, or gloss coatings – For elevated texture and smudge resistance

Box Styles That Fit Every Cap Type

From flat brims to curved visors, we engineer custom structures to fit and protect.

• Two-piece setup boxes – Premium feel for unboxing and retail displays
• Mailer-style boxes – Perfect for DTC and eCommerce fulfillment
• Pillow or gable boxes – Great for gifting or lightweight merchandising
• Magnetic closure boxes – Sleek and secure for luxury collections
• Custom die-cut inserts – Keep hats upright, unbent, and dust-free

Printing That Wears Your Brand Well

We help you design packaging that reflects the energy and identity of your hat line.

• Full-color CMYK or Pantone printing
• Space for logos, size info, style names, and QR codes
• Foil stamping, embossing, or spot UV – Add street-style or luxury details
• Interior print for care instructions or brand storytelling

Smart Features for Retail, Shipping & Gifting

We build for real-world durability and first-glance impression.

• Flat-packed or assembled options
• Auto-lock bottoms or glued seams for easy assembly
• Ventilation holes or fabric-protective liners for long-term storage
• Recyclable, compostable, and eco-conscious options available

The 3Ps of Baseball Cap Packaging

Presentation

Bold, clean branding turns your cap into a high-value retail item or gift.

Preservation

Protective coatings and secure inserts keep shape, color, and embroidery intact.

Protection

Sturdy board prevents dents, folding, or crushing during delivery or display.

Why 5000+ Fashion & Merch Brands Trust Us

From streetwear startups to global lifestyle names, we help brands deliver headwear with confidence and flair.

• No minimums – Great for limited drops, promos, or seasonal lines
• Free design and structure support
• Fast, U.S.-based production and fulfillment
• Sustainable and retail-ready materials
• Expert support from people who know product packaging inside out

Get a Free Quote Today

Give your caps the packaging they deserve—designed to hold shape and build brand. Call 0000 or email us now to start your custom printed baseball cap packaging project with Custom Boxes Lab.

When measuring a custom box, there are a few technical specifications that must be considered to ensure proper design, manufacturing, and fit for the product. Here are the major technical things to measure a custom box:

Inside Dimensions (Critical for Product Fit)

• Length (L): The longest side of the box measured inside from one corner to the opposite corner.
• Width (W): The shorter side of the box measured inside perpendicular to the length.
• Depth/Height (D or H): Measured inside from the bottom to the top opening of the box. Always specify that dimensions are given in Length × Width × Height.

Outside Dimensions (Important for Shipping & Storage)

• Measure the outer surfaces of the box including material thickness.
• Outside measurements are used for pallet stacking, warehouse spacing, and shipping compliance.

Material Thickness (Board Caliper)

• The thickness of the packaging material (e.g., corrugated board, rigid stock, cardstock).
• Impacts both the internal usable space and external dimensions.

Flap Measurements

• For boxes with flaps (e.g., mailer or shipping boxes), measure:
• Inner flaps: Ensure they meet in the middle without overlapping too much.
• Outer flaps: Allow proper sealing without gaps.

Tolerances

• Account for manufacturing tolerances (usually ±1/16" or ±2mm depending on material).
• Ensure the product fits without being too tight or loose.

Volume Capacity

• Calculate internal cubic capacity (L × W × H).
• Helps in determining how much space the product will occupy and shipping efficiency.

Product Orientation

• Decide how the product sits inside the box and measure accordingly.
• Orientation affects whether length or width is the primary dimension.

Die-Cut Openings or Windows

• Measure exact placement, height, and width for any cutouts.
• Ensure structural integrity when adding windows.

Printing Bleed & Safe Zones

• Include measurements for:
• Bleed area: Extra space beyond the cut line for printing.
• Safe zone: Inner area where critical text or logos should be placed.

Closure Type & Locking Tabs

• Measure slots, tabs, or locks for boxes with custom closures.
• Precision is required to avoid misalignment during assembly.

Packaging Style

• Folds, creases, and scores must be measured for accurate dieline creation.
• Different styles (e.g., RSC, tuck-end, mailer, sleeve) require specific panel measurements.