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Articles on designing your own custom merch, growing your brand, and managing manufacturing as a small business.

How to Ship a Hat


Designing custom hats is EASY with The/Studio, but maybe you’re stuck on how to ship them out! Here’s everything you need to know.

So you’re new to the hat business! Well, first of all, congratulations on your new business. Whether you have a hat brand or you are just adding hats to your existing merch brand, you are probably wondering how you should ship them to their new owner.

Not to worry! We’re going to go over everything you need to know to start shipping those hats out. Hopefully you ordered your custom hats from The/Studio, but if not, more on that later. Either way, we’ll get you all sorted out.

custom hats in black and pink

Shipping Services for Hats

First things first, you need to figure out what shipping service you are going to use. Of course, you’ll want to choose the service that will save you the most money but remain reliable. Cheap shipping isn’t much help if your hats go missing en route to their new owner, after all.

We have found that USPS is the cheapest mainstream shipping option. Using Pirate Ship offers even more of a discount, but do your research because depending on where you live, the shipping cost can vary.

What Should I Ship Hats In? 

It’s very important that you choose the proper shipping materials to ship a hat. You want to pay close attention to the packaging you choose to ship a hat in because if you choose packaging that’s too small, it will damage and bend the hat—and your customer won’t be happy. Like with the shipping service, you’ll want an economical choice, but it also has to look professional! Below we’ve listed a few pointers.

  • DON’T use a poly mailer. This will ABSOLUTELY damage the hat.
  • DO use a 8 x 6 x 4 box or a 8 x 6 x 6 box. These are the most common size boxes to ship a hat in, and will provide structure and support for your hat. Use a 8 x 6 x 4 box for trucker-type hats or hats that fold easily and won’t be damaged by doing so. Higher quality hats should always be shipped in a 8 x 6 x 6 box, because you need plenty of room to not have to fold the hat. These dimensions will work perfectly for a high-quality hat.
  • DO keep in mind that most hats in an 8 x 6 x 6 box weigh about eight to nine ounces. These will usually ship out First Class for around $3.50-$5.00 depending on where the hat is being shipped, at least if using USPS. 
  • DON’T just put the hat in the box without protective plastic. We put every custom hat into a plastic sleeve when we are shipping them out. This will give extra protection so your hat isn’t scuffed or crushed.

Follow the tips above and you are on your way to shipping out awesome, high-quality hats to your customers (and having them arrive in good condition).

Need More Hats to Ship? 

We got you covered! Work with The/Studio to create custom hats that are just waiting to be shipped out. 

Contact one of our Creative Specialists or use our Create Tool (linked below) to get started making your own hats!

Design and Ship Your Custom Hats Now




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