Custom Hat Packaging

Yes. We size by internal diameter and height and can integrate brim spacers and crown support rings for styles that need stabilisation during transit.

Measure the brim at its widest point and the total height from base to crown top. Add 1–2 cm of clearance on each dimension, enough so the hat sits centered without the brim touching the wall or the crown pressing the lid.

Sometimes. Fedoras with similar brim diameters can often share a size. But putting caps and wide-brim hats into the same box spec creates fit and movement problems. When the internal dimensions aren't matched to the hat, the hat moves, and movement is what causes damage.

Yes. Crown supports and brim spacers can be reordered on their own as long as your box structure hasn't changed. If you've updated the box spec, let us know, and we'll confirm compatibility before production.

It depends on board thickness and structure. A standard single-wall cardboard hat box is generally built to handle around 8 kg of stacking load. If your fulfilment setup involves heavy stacking or warehouse storage, we can spec a heavier board to match those conditions.

For e-commerce, yes, in most cases. The presentation box protects the hat. The outer shipper protects the presentation box. Without it, dents, dirt, and handling pressure go straight to the surface of the branded carton. We can design both to work together if you need a dual-layer setup.