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Custom Hat Boxes

Hats are more than just a fashion. They require unique packaging with colourful designs. Regardless of whether you own an impressive selection of fashionable fedoras, baseball caps, or sun hats, it is important to protect them. Hat boxes make for great storage and organisational solutions. It is crucial to select the best custom boxes for your hats. You can find everything you need from custom designs to functional storage solutions.

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Why Choose Healey Packaging?

Premium printing, sustainable materials, fast turnaround, and reliable UK-wide service.

High Quality Printing

Sharp details, rich colours, premium print results.

No Minimum Order

Order from just 100 boxes — ideal for small runs.

Custom Sizes & Styles

Perfect tailored fit — at no extra design cost.

Eco-Friendly Materials

Recyclable, biodegradable, and FSC-certified.

Fast Turnaround

Quick production + reliable delivery times.

Free UK Shipping

Standard orders ship free across the UK.

Premium Hat Packaging for Style, Storage & Protection

Looking for reliable and elegant solutions to store, ship, or display your hats? Our custom hat boxes are designed to preserve the shape, style, and quality of every type of headwear — from fedoras to fascinators, trilbies to baseball caps. Whether you’re a retailer, event organiser, or simply passionate about hat storage, we offer the best hat boxes for storage, gifting, and branding.

Buy Hat Boxes Online – Style Meets Practicality

With hat boxes for sale in a variety of sizes, colours, and materials, we cater to every need — whether it’s a large hat box for wide-brim hats, a small hat box for berets, or cap boxes tailored for baseball caps. Each box is built to offer superior protection while enhancing presentation.

Available in:

  • Round hat boxes – timeless and elegant
  • Cardboard hat boxes with lids – durable, protective, and eco-friendly
  • White hat boxes, black hat boxes, and more – choose a finish to match your branding or event

Custom Hat Boxes for Every Purpose

Retail & Bulk Hat Boxes

Our hat boxes wholesale options are perfect for shops, boutiques, and fashion brands. These boxes are customisable with your logo, colours, and print designs — ideal for creating a consistent retail experience.

Cap Box Packaging

Need a box for caps or a specific cap box size? Our cap box storage solutions are designed to protect the brim and structure of baseball caps and snapbacks — whether for display or delivery. They’re a must for sports brands and eCommerce stores.

Gifting & Special Occasions

Some folks want that old-school vintage charm. Others go straight for minimal and modern. Either way, we’ve got hat boxes that suit the vibe—weddings, birthdays, big brand events, you name it. And yep, you can add your own branding or message to make it personal.

Durable and Quality Materials

Our hat packaging boxes are crafted from top-notch materials including cardboard, kraft, and rigid stock. These options ensure protection against damage and keep your products in pristine condition. Select cardboard hat boxes for lightweight needs or rigid boxes for luxurious gifting.

Eco-Friendly Packaging Solutions

We’re not just ticking a green box—we actually care about how this stuff gets made. Most of what we make is done with recycled or eco-friendly board—we’ve made that a priority. We keep tweaking things—less waste here, better materials there. It’s a work in progress, but we take it seriously. If your brand leans eco, we’ll get along just fine.

Cardboard Hat Box Options

We use high-quality, rigid and corrugated cardboard to create sturdy, eco-conscious hat packaging boxes. All our boxes:

  • Come with secure lids to protect from dust and deformation
  • Are available in custom sizes, including extra large hat boxes
  • Can be ordered in bulk quantities for wholesale pricing
  • Include cheap hat boxes options without compromising quality

Advanced Printing Techniques for Premium Results

Highlight your branding with innovative printing options. We can print in full CMYK for bold colours, and if you’re after something extra, we’ve got options like spot UV or embossing to give your design a bit more edge. Whether it’s vintage hat boxes or modern cap box packaging, we ensure unmatched precision and appeal.

Perfect for All Hat Types

Our hat boxes for women and men cater to a variety of styles. From baseball hat boxes to elegant packaging for professional events, you’ll find options that suit every occasion. Bulk purchases are also supported.

Why Choose Our Hat Boxes Packaging?

As specialised hat boxes suppliers, Healey Packaging understand the unique requirements of storing and presenting headwear. Our products are:

  • Designed specifically for optimal hat protection
  • Available in various sizes and styles to suit different hat types
  • Customisable with your branding, colours, and designs
  • Made from durable, high-quality materials
  • Eco-friendly options available
  • Competitively priced, especially for wholesale orders

Got a boutique line that needs something elegant? Or maybe you’re after bulk hat boxes for retail? Either way, just give us a shout—we’ll help you figure out what works best for your products.

Ready to Elevate Your Hat Packaging?

Generic boxes just don’t cut it when it comes to protecting hats. We’ve seen too many arrive crushed, dusty, or just… underwhelming. We don’t just make boxes—we build packaging that protects your hats and matches your brand’s look and feel. Got something unique in mind? Great. We’ll walk you through the options and make sure it turns out exactly how you imagined.

Got Questions About Hat Boxes? We’ve Got You.

Can you do different sizes for hat boxes?

Yeah, absolutely. We make them in all sorts of sizes—small, oversized, tall, flat—you name it. Whether it’s a cap, a floppy wide-brim, or something in between, we’ll build the box to fit your product, not the other way around.

Will these work for both men’s and women’s hats?

Yeah, they’re totally fine for either. We’ve done boxes for all sorts—men’s caps, women’s fascinators, even a few that don’t really fit into one category. Just let us know what kind of hat you’re working with, and we’ll shape the box around that.

Do you offer hat boxes wholesale?

Absolutely. Our wholesale options come with competitive pricing and consistent quality — ideal for retailers and manufacturers.

What printing options are available?

We offer full custom printed hat boxes using CMYK or Pantone colours. You can include logos, product visuals, taglines, or unique patterns.

Are these strong enough for shipping caps?

Yep, especially the ones with structured brims. We’ve designed cap boxes that hold their shape and protect the front panel in transit, so your product arrives looking just right.

Do you use eco-friendly materials?

Most of the time, yeah. Kraft board, recyclable card—those are our go-to. If you’re after something properly green (like biodegradable windows or compostable print), just say so. We’ll make it happen.

Explore Our Premium Packaging Options

Mix and match materials, printing methods, inks, finishes, and add-ons to build packaging that feels completely on-brand. Start with the material, then move through print and finishing to see what fits your product best.

Strong Corrugated cardboard sheets

Corrugated Cardboard

Shipping • E-commerce • Heavy items

Fluted middle layer for strength and cushioning. Ideal for mailer boxes, shipper cartons, and any product that needs extra protection during delivery.

DurableProtective
Eco Natural brown kraft board

Natural Brown Kraft

Eco brands • Food • Lifestyle

Rustic, uncoated look that feels honest and sustainable. Great for bakery, subscription boxes, and earthy lifestyle brands that want a natural tone.

RecyclableOrganic feel
Premium White SBS bleach card

SBS / Bleach Card

Beauty • Pharma • Retail

Bright white, smooth surface for sharp printing and rich colors. Perfect for cosmetic cartons, medicine boxes, and premium retail packaging.

High print qualityClean white
Luxury Black kraft packaging board

Black Kraft / Black Card

Luxury • Gifts • Apparel

Deep matte black stock that pairs beautifully with metallic foil. Best for luxury rigid boxes, apparel packaging, and special gift sets.

Premium lookFoil-ready
Flexible Digital printing press

Digital Print

Short runs • Variable data

Great for smaller quantities, seasonal packaging, or designs that change often. Fast setup with strong color output and no plate costs.

Low MOQFast
Classic Offset printing rollers

Offset Print

Larger runs • Brand colors

Industry standard for high-volume packaging. Ideal when you need consistent Pantone colors and the most economical cost per unit at scale.

Sharp detailCost-effective
Spot effects Scodix enhancement print

Scodix Enhancement

Tactile • Raised effects

Digital enhancement that adds raised UV, textures, and metallic-style effects to selected areas, creating a premium, touchable finish.

3D feelHighlight details
Gloss UV print on packaging

UV Print

High gloss • Rich color

Cured with UV light for instant drying and strong color density. Works well when you need vibrant prints on coated boards.

ShinyDurable
Standard CMYK ink cans

CMYK Process Inks

Full color • Gradients

Ideal for photography, gradients, and detailed artwork. Most packaging projects start here before adding special colors or finishes.

Full colorVersatile
Branding Pantone ink swatches

Pantone Spot Inks

Exact brand tones

Used when color accuracy is critical. Pantone inks lock in signature brand colors across different print runs and materials.

ConsistentOn-brand
Bold Screen printing ink layers

Screen Printing

Thick ink • Bold coverage

Screen printing lays down a thicker layer of ink, creating vibrant solid colors and strong opacity. Best for bold logos, solid shapes, and designs that must pop even on darker materials.

OpaqueVibrant
Eco Eco friendly vegetable inks

Soy / Vegetable Inks

Eco packaging

Lower-VOC options that support more sustainable packaging. Often paired with kraft stocks and minimalist designs.

Low VOCEco-minded
Matte Matte laminated box

Matte Lamination

Soft touch • Low glare

Gives packaging a smooth, elegant feel with reduced shine. A favourite for luxury, cosmetic, and tech products.

PremiumModern
Gloss Gloss laminated packaging

Gloss Lamination

Shiny • Eye-catching

Adds shine and extra ink protection. Works well for bold colors, retail shelves, and youth-focused brands.

ShinyScuff-resistant
Tactile Soft touch coated box

Soft-Touch Coating

Luxury feel

Creates a velvety, rubberised feel that makes customers want to hold the box longer. Ideal for high-end unboxing experiences.

VelvetyPremium
Highlight Spot UV gloss on box

Spot Gloss UV

Logo & details

High-gloss UV applied only to selected areas like logos or patterns, so they catch the light without making the whole box shiny.

ContrastLogo focus
Luxury Gold foil stamping on packaging

Foil Stamping

Gold • Silver • Custom

Metallic foil pressed into the board for instant shelf impact. Great for logos, borders, and badges on gift, cosmetic, and rigid boxes.

MetallicPremium detail
Raised Embossed packaging surface

Embossing

Raised detail

Embossing lifts selected artwork from the surface, giving logos, patterns, and brand marks a premium 3D raised effect that customers can feel instantly.

3D liftPremium texture
Depth Debossed packaging surface

Debossing

Pressed detail

Debossing presses artwork into the board, forming an elegant recessed impression. Works beautifully for minimalist luxury packaging and fine-detail branding.

IndentedLuxury
Windows Box with die-cut window

Die-Cut Windows

Show the product

Custom window shapes let customers see the product before they buy. Can be left open or backed with clear PET where needed.

RetailProduct focus

Loved by Real Customers

Liz Wheelhouse
★★★★★

“We reached out to Healey Packaging to help us create bespoke shaped boxes… the final product looked amazing and was very well received.”

November 18, 2025
Ash
★★★★★

“Very happy with the service and print quality. Patient with revisions and great communication. A very positive experience.”

September 18, 2025
Vanessa Scott
★★★★★

“The printing quality was excellent and Alex was incredibly helpful. I’ll definitely use Healey Packaging again.”

June 6, 2025
Adrian Tang
★★★★★

“Excellent service, very good quality and sharp printing. Highly satisfied with the results.”

May 7, 2025
G. Mitev
★★★★★

“Our custom boxes arrived exactly how we imagined. Great quality and friendly support from start to finish.”

April 21, 2025
Scott Anthony
★★★★★

“Really great branded hat boxes. Perfectly printed and excellent service. Will definitely return.”

April 14, 2025
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