A proper hat box would suffice.
If you don't have one, get a 18x18x10" box, fill it with foam packaging bits or newspapers.
Because I don't live in the US, I don't know. Maybe western wear shops? Don't know if they sell empty hat boxes.Did not get the hat box with it. Do you know of any stores that carry these size boxes?
I echo everything Deadly states in this post......adding one thing. Check the dimensions of the box and check the USPS online calculator....size matters. If you keep it under, in the US I think it is 16x16x7" you get the cheapest rate.My packaging depends on my purpose in shipping them. If it’s going to a hatter for reblocking I don’t do much more than place it inside a plastic bag and box it up. I don’t allow for any acute bends, but the hat can arrive bit misshapen.
If I need the hat to arrive in the same condition as it was before it shipped, such as when I’m selling a hat, I’ll go to more effort. I often cut a strip of cardboard deeper than the depth of the crown and long enough to form a ring when the ends are taped to allow the crown to rest inside. I’ll put the hat in a plastic bag and then put the ring in a box and set the hat crown down into the inside of the ring. I’ll use packaging materials to support the hat and keep it centered in the box. The box has to be big enough to not touch the hat: only the cardboard ring should make contact with the hat (or the bag that the hat is in). A too small box will cause the hat to deform. I always use a top layer of bubble wrap or heavy paper to protect the hat if the receiver isn’t careful and opens the box with a knife. Also, make sure the box is of a sufficient quality to allow for rough handling in shipping without damaging the hat.
On some less expensive hats I’ll forgo the “ring” and just pack the hat with lots of packing materials...this is a great way to get rid of foam peanuts if you have them.
I echo everything Deadly states in this post......adding one thing. Check the dimensions of the box and check the USPS online calculator....size matters. If you keep it under, in the US I think it is 16x16x7" you get the cheapest rate.
Canada it is 35 inches.For US shipping the magic number is 36 inches (length + height + width). Go over 36” combined and prices go WAY UP WAY FAST!