Cheapest Way to Ship Hats
Structured hats need rigid boxes to maintain their shape, while beanies can go in simple poly mailers.
Shipping Options for Hats
Shipping hats depends entirely on the hat type. Soft hats like beanies and bucket hats can be folded and shipped in poly mailers for minimal cost. Structured hats like baseball caps, fedoras, and cowboy hats need rigid boxes that maintain the hat's shape during transit. The challenge with structured hats is that they are lightweight but bulky, meaning dimensional weight pricing can make shipping more expensive than the hat's actual weight would suggest. Stuffing the crown with tissue paper and using a hat-sized box are essential.
| Service | Carrier | Est. Cost | Speed | Best For |
|---|---|---|---|---|
| Ground AdvantageRecommended | USPS | $5-8 | 2-5 days | Most hat shipments including structured caps |
| Priority Mail | USPS | $8-12 | 1-3 days | Premium or time-sensitive hat deliveries |
| FedEx Ground | FedEx | $10-15 | 3-7 days | Bulk hat shipments and oversized hat boxes |
| UPS Ground | UPS | $10-15 | 3-7 days | Business wholesale hat orders |
Packaging Tips for Hats
Pro Tips
- For baseball caps, flip the brim down and stuff the crown firmly with tissue paper to hold its shape throughout transit.
- Beanies and soft knit hats can be rolled and shipped in lightweight poly mailers to save significantly on packaging costs.
- If shipping a wide-brimmed hat like a cowboy hat, use a specialty hat box or create a custom insert from cardboard.
Frequently Asked Questions
Stuff the crown firmly with crumpled tissue paper to maintain its dome shape. Place the cap brim-down in a box that is just slightly larger than the hat, with minimal empty space. Fill any remaining gaps with tissue paper to prevent the cap from shifting or being compressed during transit.
Yes, beanies and other soft, unstructured knit hats can be rolled or folded and shipped in a poly mailer or padded envelope. They are flexible and will not be damaged by the compression of an envelope. This is the cheapest way to ship soft hats, often costing just $4-5 via USPS Ground Advantage.
Structured hats require boxes that are relatively large compared to the hat's actual weight. Carriers use dimensional weight pricing, which calculates cost based on package size rather than actual weight when the box is large but light. To minimize this, use the smallest box that safely fits your stuffed hat without compressing it.
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