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Hat Mailer Boxes
Mailer boxes made to protect caps and hats in transit without crushing the crown or bending the peak.
About our box
Hat Mailer Boxes, made to your size
Caps and hats lose their shape easily in the wrong packaging. Our hat mailer boxes are sized around your headwear, with enough depth for the crown and room for the peak, so every cap arrives looking new.
Why choose our hat Mailer Boxes
For headwear brands, a crushed cap is a return waiting to happen. A made-to-measure box protects the shape, looks great on the doorstep and pairs perfectly with our custom caps.
Popular uses
- Snapbacks and fitted caps
- Dad caps and trucker caps
- Bucket hats
- Beanies and headwear bundles
- Merch drops
Materials, print and finishes
- Sized for crown and peak
- Single or multi-cap sizes
- Inserts to hold the cap shape
- Printed inside and out
Making caps too? Order custom caps and hat mailer boxes together for one matching delivery.
Sizes and dimensions
Every order of hat Mailer Boxes is made to your dimensions in millimetres (length × width × height). Not sure of the size? Choose “Not sure — suggest a size” in the options above and tell us what you are packing, and we will recommend dimensions and show them in your mock-up. You can also order several sizes in the same design to cover your whole range.
Related packaging
Comparing options? Take a look at Custom Caps, Branded Mailer Boxes and Square Mailer Boxes, or browse all custom mailer boxes and our wider custom packaging range.
How to order
Choose your size and options above and request a free quote. We reply within 24 hours with your price and a free 3D mock-up, and nothing is printed until you approve it. Orders are delivered across the UK in 12–14 working days; see our delivery information. The “From” price is our bulk price per unit, excluding VAT, and larger quantities bring the unit price down. Selling clothing too? We also make custom apparel to ship in your boxes.
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Specifications
| Best for | Caps, snapbacks and hats |
|---|---|
| Style | Self-locking mailer, tape-free |
| Board | Kraft or white corrugated (E-flute or B-flute) |
| CMYK and Pantone, outside, inside or both | |
| Finishes | Matte, gloss or soft-touch; foil, spot UV, embossing |
| Size | Made to your inside dimensions (mm) |
| Recyclable | Yes, with UK paper and card recycling |
| Minimum order | Low minimums |
| Delivery | 12–14 working days after approval, UK-wide |
| Category | Custom Mailer Boxes |
Fill your boxes with your own merch
Hoodies, tees, sets, caps and socks — cut and sewn to your design from 20 pieces per style, packed in your boxes and delivered together.
Explore custom apparelHow it works
Tell us your box
Size, print and quantity — or ask us to suggest a size.
Free 3D mock-up
See your design on the box before anything prints.
We print and make
Printed, die-cut and quality checked.
Delivered flat
Tracked UK delivery in 12–14 working days.
Questions about Hat Mailer Boxes
Will the box hold the cap’s shape?
Yes. We size the box to the cap, and can add an insert that supports the crown.
Can one box hold several caps?
Yes. We can make larger boxes that fit two, three or more stacked caps.
How much do hat mailer boxes cost?
The “From” price on this page is our bulk price per unit, excluding VAT. Your exact price depends on size, quantity, print and finish, and we send it with a free mock-up within 24 hours.
How long does delivery take?
12–14 working days after you approve your mock-up, with tracked delivery anywhere in the UK.
Ready to see your box?
Send your size and logo — free 3D mock-up and quote within 24 hours.