Shipping hats require a blend of care and strategy. From selecting the right packaging to choosing the best shipping method, every detail matters. Learn how to ship different types of hats, ensure they arrive in perfect condition, and find cost-effective solutions to keep your customers satisfied in this blog.

How to Safely Ship Different Types of Hats

Each hat is unique, so the packaging can vary greatly. When figuring out how to ship a hat, experiment with different options, including those presented here, to find what works best for your specific needs.

Shipping Tips for Baseball Caps and Visor Hats

When dealing with small, lightweight hats like baseball caps and visor hats, some might think that good packaging isn't really necessary to ship cap. However, just imagine your customers receiving a poorly packaged cap that got damaged during transportation—not the best experience. To prevent this, you'll need a small but sturdy box. For baseball caps, a box around 8x8x4 inches usually works well. 

Next, use protective materials like tissue paper, bubble wrap, and packing peanuts or air cushions. If you’re just starting out, dollar stores are a good place to find these items. For higher order volumes or wholesale hats buying in bulk will be more cost-effective. Lastly, use strong packing tape to seal the box securely.

How to Ship Wide-Brimmed Hats, Panama Hats, and Fedoras

Shipping wide-brimmed hats and fedoras requires careful packaging to keep the crown and brim intact. Select a box that’s large enough to accommodate the hat without bending the brim. For most wide-brimmed hats, a box around 14x14x7 inches should work, while for fedoras, a what size box for shipping hats - 12x9x6 inches (as shown in our store) is suitable. 

To support the crown of the hat, use an insert or padding to help maintain its shape. Stuff the inside of the hat’s crown with tissue paper to keep it from losing its form. 

Next, wrap the hat in bubble wrap and/or tissue paper, paying special attention to the brim, and use packing peanuts, air cushions, or crumpled paper to fill any empty spaces around the hat. Or, cut a piece of cardboard with the same diameter as the hat’s crown and fasten it as shown in the video below. 

Best Practices for Shipping Cowboy Hats

Use large enough boxes to ship hats without bending the brim. A box size of approximately 16x16x8 inches is often suitable for cowboy hats. Add packing materials, or an appropriately sized hat insert into the crown to help maintain its shape. 

You can also use a hat protector to cover the crown of the cowboy hat. These protectors are typically made from durable plastic or foam, and they help prevent the brim from bending or losing its shape during transit.

Position the hat in the center of the box and fill any empty spaces to prevent the hat from shifting and provide additional cushioning. However, avoid overpacking, as this could put pressure on the hat and lead to damage.

In case you’ve got a more specifically shaped hat, you can try this method how to ship a cowboy hat:

Shipping Bucket Hats, Beanies, and other Hats with Envelope

How to ship a hat without a box? When shipping hats like beanies, winter hats, and bucket hats that can be folded without losing their shape, you can opt for a poly mailer or padded envelope. 

Poly mailers are lightweight and durable, while padded ones offer extra built-in cushioning. Fold the hat carefully—bucket hats in half, beanies or winter hats flat—to avoid creasing.  You can wrap the hat in tissue paper or place it in a plastic bag for added protection against moisture or dust. Make sure it fits comfortably without being overstuffed. If you’re using a poly mailer, you might add a small piece of bubble wrap for extra protection.

Best and Cheapest Ways to Ship Hats and Caps

With so many options, finding the best shipping options for hats without cutting into profits can be challenging.  So, let’s explore some effective choices for shipping hats. 

Cost-Effective Shipping Options for Hats

Choosing the most price-efficient shipping method for hats within the USA can significantly reduce your shipping expenses. Here’s a comparison of the most affordable options for shipping a hat with dimensions of 8x8x4 inches and a weight of approximately 10 ounces. For this example, we’ll consider shipping from Los Angeles to New York to see how much to ship a hat:

• UPS Ground Saver: $5.61 (5 delivery days)
• USPS Ground Advantage: $5.62 (5 delivery days)
• Sendle Standard: $5.87 (5 delivery days)
• UPS Ground: $8.43 (5 delivery days)
• USPS Priority Mail: $10.07 (2 delivery days)
• UPS 3 Day Select®: $13.03 (3 delivery days)

Please note that these rates are for labels purchased through online accounts. Rates may differ significantly if you buy labels directly from a UPS or FedEx store. Services like Stamps.com provide USPS-approved postage and UPS discounts, while Shippo offers savings across USPS, UPS, FedEx, and DHL Express. For individuals and small businesses, ShippingEasy is ideal, providing discounted rates for USPS and UPS.

Comparing Shipping Carriers for Fast Hat Deliveries

The second most important factor for customers, after price, is delivery time. In today’s fast-paced world, no one wants to wait too long for their purchase. Therefore, you need to balance the fastest delivery hat times with the price your customers are willing to pay.

For a package with dimensions of 8x8x4 inches and weighing 10 ounces, shipping from Los Angeles to New York, here are the delivery times and costs for various carriers:

• FedEx First Overnight®: $174.33 (less than a day)
• UPS Next Day Air Saver®: $43.22 (1 day delivery)
• USPS Priority Mail Express®: $47.25 (1 day delivery)
• UPS Next Day Air®: $49.76 (1 day delivery)
• USPS Priority Mail®: $10.07 (2 day delivery)
• UPS 2nd Day Air®: $13.12 (2 day delivery)

To easily calculate shipping costs and determine the best option, consider using an online shipping calculator.

Common Mistakes to Avoid When Shipping Hats + Expert Tips

Here’s some expert advice to ensure that when you ship a hat, it always arrives in top shape.

Best Practices for Labeling and Handling Hat Shipments

Before heading to the post office, ensure your label is correct. It might affect delivery speed, shipping cost, and your customer’s impression of your service.

Essential Information for Labels

Your shipping label should be comprehensive and clear. Start by including both the sender’s and recipient’s names, addresses, and contact numbers. Specify the shipping method and who delivers the hat, e.g. USPS Priority Mail or UPS Ground, and make sure to add the tracking number for easy monitoring. Accurate package weight and dimensions are vital to avoid delays or additional charges. Lastly, include a scannable barcode for tracking and delivery confirmation.

Platforms for Creating Labels

To design and print your shipping labels, you can use these platforms:

• Maestro Label Designer: This platform is ideal for creating custom labels and barcode generators.
  
  
• Adobe Creative Suite: Perfect for advanced designs, allows you to create detailed labels from scratch or modify existing ones.
  
  
• Canva: Provides a wide selection of label templates suitable for various needs.
  
  
• Pirate Ship: Offers an easy solution for purchasing and printing shipping labels. 

Printing and Placing Labels

For printing labels, use an inkjet or laser printer, adjusting settings to match the label paper type and size for clarity. Or, opt for a dedicated label printing machine for high-quality results. You can also print labels at the post office if you prefer professional help.

When placing labels on the box, position them flat on the largest side, avoiding seams and corners. If the label could be damaged, protect it with a clear plastic sleeve or additional tape, but keep the barcode and essential information visible.

Common Shipping Mistakes and Tips to Ensure Customer Satisfaction

• Avoid using newspaper or colored tissue paper, as ink may transfer to the hat.
  
• Remove any decorative elements from the hat and pack them separately to prevent friction and damage.
  
• Be cautious of extreme temperatures; avoid shipping during very hot or cold weather.
  
• Use custom-made hat boxes designed for optimal protection and enhanced presentation.
  
• Label the package as "fragile" to alert handlers to treat it with care for delicate items like straw cowboy hats.
  
• Use arrows to indicate the correct orientation of the package to ensure proper positioning and minimize mishandling.
• Don't mix with other heavy and small items to prevent damaging the hat
• Use a hat protector in between hat if you are shipping more than one hat.
• Check the fragile parts of hat such as feather, buckle, ribbon, etc. to prevent deformation.