hat mailer box

Designed for eCommerce, Merch Drops & Direct Shipping

Our custom hat mailers are ideal for streetwear brands, sports team merch, luxury hat labels, and corporate giveaways.

Durable Materials That Protect Your Product & Promote Your Brand

We craft each box using premium, sustainable materials that balance strength and style.

• Corrugated cardboard: Strong enough for shipping, light enough to save costs
• White or kraft E-flute: Great for high-end printing and protection
• Matte, gloss, or soft-touch finishes: Add polish and visual appeal
• Recyclable and eco-friendly: Brand smart and sustainably

Sized and Styled for Every Hat Type

From snapbacks to sun hats, we create the perfect structure for your headwear.

• Flat-pack mailers for low-profile caps
• Taller boxes with structured inserts for wider brims
• Foldable or auto-locking boxes for easy assembly
• Optional handles, sleeves, or built-in hangers for retail-ready use

High-Impact Printing That Builds Brand Loyalty

Your box isn’t just a container—it’s a canvas for your brand message.

• Inside and outside custom printing
• Spot UV, hot foil stamping, or soft-touch effects
• Embossed logos and taglines
• QR codes to link to your shop, lookbook, or socials

Add-Ons That Complete the Unboxing Experience

Turn each delivery into a branded moment your customers remember.

• Custom tissue paper, wrap bands, or sticker seals
• Care cards or thank-you inserts
• Hat size guides or promo flyers
• Ribbon pulls, branded tags, or reusable box styles

The 3Ps Approach

• Presentation: Make a bold first impression with a mailer box that elevates your brand and showcases your hat’s personality.
• Preservation: Our smart box engineering and tailored inserts help preserve the hat’s shape, brim, and stitching during transit.
• Protection: Thick, crush-resistant materials and optional padding guard against impacts, dust, and moisture.

Why 5000+ Apparel & Accessories Brands Trust Us

We’re the go-to partner for fashion-forward packaging.

• No minimum order quantity
• Free dieline and expert packaging consultation
• Fast U.S. production and delivery
• Eco-conscious materials with high-end feel
• Dedicated support from hat packaging pros

Get a Free Quote Today

Send your hats in packaging as iconic as the styles inside. Call 0000 or email us now to start your custom hat mailer box order 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.