Custom Hat Box with Insert

Internal inserts add protection and style by holding the hat in place and preventing movement. Combined with elegant outer packaging, these boxes highlight the product’s value while ensuring it arrives in flawless condition.

Materials

We use high-quality materials for both the outer box and interior insert:

• Rigid board – offers a luxury feel and strong protection
• Corrugated cardboard – reliable for shipping larger quantities
• Kraft board – sustainable and visually appealing
• Cardstock – suitable for lightweight and short-term display

Sizes

Every hat style demands a tailored box size and insert fit:

• Standard boxes for caps and visors
• Deep round boxes for wide-brimmed hats
• Custom-sized inserts to support crown and brim
• Dual-compartment inserts for accessories like pins or bands

Prints

Customize your hat packaging with eye-catching and brand-driven printing:

• Full-color printing with matte or gloss finish
• Eco-safe inks for vibrant and safe designs
• Logo application on box and insert surface
• Optional interior graphics for enhanced presentation

Add-ons

Upgrade your hat box and insert with thoughtful customizations:

• Die-cut foam or cardboard inserts
• Satin linings or fabric-wrapped platforms
• Magnetic closures, ribbon pulls, or handle options
• Embossing, foil stamping, and spot UV finishes

Types of Boxes

Choose a structural design that complements both the hat and insert:

• Two-piece rigid boxes with shaped inserts
• Flip-top boxes with molded internal support
• Drawer-style boxes with pull-out inserts
• Round boxes with cushioned inner base

3Ps Approach

Our Presentation, Preservation, and Protection framework ensures top-tier packaging for every hat box with insert.

Presentation

Inserts elevate the product visually while helping organize the layout, ensuring your brand leaves a strong impression.

Preservation

Each insert is built to cradle the hat securely, preserving its form and avoiding bends, wrinkles, or crushing.

Protection

Sturdy materials and snug-fitting inserts protect the hat from impact, pressure, and environmental exposure during shipping or display.

Upgrade to Premium Packaging

Add a luxury edge to your hat packaging with advanced finishes:

• Velvet-covered or printed inserts
• Debossed logos on the insert platform
• Gold or silver foil lining for insert edges
• Soft-touch, linen, or embossed exterior wraps

Why Choose Us?

We understand the importance of combining structure with elegance in hat packaging. That’s why we offer:

• Free insert design with dielines and 3D previews
• Eco-conscious packaging material choices
• Support for low and bulk order volumes
• Fast turnaround and attentive support team

Get A Quote

Enhance both form and function with a hat box and insert combo. Call us at 0000 or email us now to receive a custom quote tailored to your needs.

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.