Corrugated Hat Box

Tailored for Headwear That’s Made to Impress

Our corrugated hat boxes are ideal for milliners, retail stores, eCommerce brands, costume houses, or promotional giveaways.

Materials That Balance Durability & Display Value

We use high-strength corrugated cardboard with premium finishes to ensure every hat arrives safe and stylish.

• Single-wall or double-wall corrugated board: Choose based on weight and shipping needs
• Kraft finish: Rustic, sustainable feel for earthy or artisan brands
• White or coated SBS: Sleek print surface for high-impact visuals
• Water-resistant lamination: Protects against moisture during storage or transit

Custom Sizing & Box Structures for Every Hat Type

We build every corrugated hat box around the size, shape, and style of your headwear.

• Round, square, or oval bases for fitted presentation
• Telescoping lid, flip-top, or tuck-top styles
• Inserts or interior rings to hold hats in place
• Stackable designs for retail storage or shipping efficiency

Print That Reinforces Brand Identity

Turn your hat box into a brand statement with high-end printing and finishing techniques.

• Full-color CMYK or Pantone printing
• Hot foil stamping for logos, monograms, or accents
• Embossed or debossed branding elements
• Inside-lid messaging, care instructions, or brand stories

Packaging Enhancements That Elevate the Experience

Add functionality and flair to your custom hat boxes.

• Rope or die-cut handles for easy carrying
• Custom tissue paper or branded inner wraps
• QR codes linking to care tips, style guides, or your online store
• Magnetic closures or tab locks for luxury finishes

The 3Ps Approach

• Presentation: Beautiful, custom-printed boxes that match the elegance or boldness of your hat designs.
• Preservation: Interior supports, thick walls, and secure lids keep your headwear safe from crushing, dust, and damage.
• Protection: From delicate fascinators to wide-brimmed hats, our packaging ensures safe delivery and storage every time.

Why Leading Fashion & Accessories Brands Choose Us

From boutique milliners to fashion brands, we deliver hat boxes that protect and sell.

• No minimum order quantity
• Free dieline and custom design consultation
• Fast U.S. manufacturing and delivery
• Eco-conscious corrugated materials
• Trusted by over 5,000+ brands

Get a Free Quote Today

Make your headwear unboxing as fashionable as the product inside. Call 0000 or email us now to start your corrugated hat box 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.