Custom Cap Boxes & Cap Packaging
Caps are one of those products where the packaging has to do a real job, not just look nice. A snapback with a stiff structured crown will lose its shape if you flatten it, and once the brim curves wrong nobody wants to buy it. We print a fair amount of cap packaging at ZEE Packaging and this is what we have learned along the way.
Crown Shape Decides Everything
At ZEE Packaging, we start every custom cap box and cap packaging design with the cap’s crown shape, because its height, curve, and structure determine the box size, fit, and internal support.
- Structured snapbacks and fitted caps need a cap box with full height, the crown cannot collapse
- Unstructured dad caps are forgiving, they fold down and a shallower cap box works fine
- Truckers with mesh backs need a bit more depth, mesh springs back
- Flat brims need a wider cap box, curved brims need less width but more height
- Beanies and knits barely need structure at all, cheapest cap packaging of the lot
Send us the cap itself if you are unsure. We measure crown height, brim length and brim curve here and build the dieline around it.
Sizes We Run Most
ZEE Packaging produces custom cap boxes in a wide range of standard and custom sizes to fit baseball caps, snapbacks, trucker hats, fitted caps, and other headwear styles.
- 8" x 8" x 5" for a structured snapback, our most ordered cap box
- 9" x 9" x 5.5" for fitted caps with a flat brim
- 8" x 7" x 4" for dad caps and unstructured caps
- 10" x 10" x 6" for truckers with deep mesh crowns
- 12" x 10" x 8" for a two cap gift set
- 7" x 7" x 3" for beanie cap packaging
Box Styles Worth A Look
ZEE Packaging offers custom cap boxes in many box styles to suit different cap shapes, presentation needs, and shipping requirements.
- Rigid two piece box lid and base, the premium cap box, holds shape perfectly
- Mailer box best selling cap packaging for ecommerce, ships direct no outer carton
- Tuck end folding carton cheapest cap box, works for soft caps and beanies
- Drawer box slides open, feels expensive, good for limited drops
- Window carton die cut opening so the front panel logo shows through
- Magnetic closure box luxury cap packaging for high end streetwear
- Corrugated shipper plain outer when your branded cap box travels inside it
Board Choice Matters Here
At ZEE Packaging, you can select the board for custom cap boxes based on crush resistance and structure that helps to protect lightweight but bulky caps from bending, denting, and deformation during shipping and storage.
- E flute corrugated our default for cap boxes, gives crush resistance without much weight
- B flute stronger, for cap packaging that ships alone across the country
- Rigid greyboard 36pt or 48pt wrapped in art paper, the luxury cap box
- 18pt to 24pt SBS printed folding carton cap box for retail shelves
- Kraft corrugated natural look, very popular with streetwear brands
A thin cardstock cap box looks fine on the shelf but it caves the moment a courier stacks something on it. For anything shipping alone we push toward corrugated every time.
Inside The Cap Box
At ZEE Packaging, you can add custom inserts, supports and protective fittings inside cap boxes to help the crown hold its shape and prevent movement during shipping and handling.
- Paperboard crown insert that holds the shape
- Tissue paper stuffed inside the crown
- Brim support card to stop the curve flattening
- Sticker seal and belly band
- Hang tag and size card
- Divider when two caps share one box
Finishing
- Soft touch lamination, streetwear brands love it
- Foil stamping the logo, gold and silver both work
- Deboss on kraft, cheap and looks sharp
- Matte film with spot UV on the brand mark
- Window patching with clear PET
- Inside print, gets photographed a lot in unboxing videos
Greener Cap Packaging
- Recycled kraft cap box with no lamination
- FSC certified board, certificate on request
- Soy based ink
- Paper insert instead of foam
- Right sized cap packaging so you are not shipping air
How We Work
- 100 unit minimum on any cap box design
- Free 3D mockup and flat proof
- Free dieline from our inhouse team
- 5 to 8 business days on urgent turnaround
- Free shipping worldwide
Frequently Asked Questions
Could you provide a price quote for a cap box?
Rough estimate is $0.55 to $1.40 per unit for folding cartons, $1.10 to $2.80 for mailer boxes and $2.60 to $6.50 for rigid boxes at moderate quantity. Cap boxes cost more than most because of the cubic size. Shipping is included in our price, but this is an estimate only so ask our team for an exact quote.
Will the box keep my snapback from getting crushed?
With the right board yes. E flute corrugated plus a crown insert holds it. A plain thin carton wont, and that is the mistake we see most.
Can we ship the cap box on its own with no outer carton?
Yes if you go corrugated mailer. We print the outside and it ships direct. Rigid boxes we normally recommend an outer shipper.
Do you supply hang tags and stickers too?
We do. Plenty of clients order cap boxes, tags and seal stickers in one job so the stock and color match.
Does a window help sell caps?
On a retail shelf it does, the front panel logo is the selling point. For online orders it just adds cost.
How do we stop the brim flattening?
A brim support card inside. It is thin paperboard and costs pennies, but it holds the curve through transit.
Can you fit two caps in one box?
Yes, we build a divider and size the box for a stacked pair. Popular for gift sets and team orders.
