A floppy brim on the beach, a cowboy hat on a ranch, or a baseball cap for an away game: hats are a necessity in so many travel destinations, but traveling with them can be tricky. You could stuff one into your checked luggage cushioned by soft socks, but the threat of damage remains should any padding come loose. You could wear it on your flight, but then you’re limited to bringing just one, and if you place it in overhead bins, you risk it being crushed by a neighboring suitcase.
When traveling with hats, I suggest a hat box, which is designed specifically to protect headwear. Some are molded for an intended style, like a cowboy hat, and others have crush-resistant shells to protect from bends or creases regardless of hat shape. Many also do double duty as storage or boast travel-friendly features like trolley sleeves. To find the best hat boxes, we tested 10 popular designs evaluating ease of use, protection, capacity, portability, and value. Here are the best options for hats of all sizes, whether you prefer an oversized hat, an iconic fedora, or a classic cap.
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Made from heavy-duty plastic, this protective case is designed to hold western-inspired hats, though we could easily see it used for other styles, too. The best feature by far is the internal sizer, which is adjustable to ensure that every hat is securely positioned in place. During our tests, we found it offered full protection to the hats’ brim and crown, and experienced no issue with maintaining the shape of the hats we placed inside.
The capacity depends on the size of the hats being packed, however, we were able to fit five small cowboy styles inside. Additionally, we were impressed by the locking latches, which are easy to open and keep everything contained well. There’s also an interior mirror, which we thought was an unexpected and thoughtful addition, and we like that the entire box is airline-approved for travel. Plus, it comes in a slew of attractive gem tones such as emerald green, deep purple, and teal, in addition to classic colors like black, tan, and brown. For a finishing personalized touch, stick-on brass name plates may be purchased separately and affixed to the front.
The Details: Fits up to 5 hats | 16 x 17.5 x 9.5 inches (outer) and 15.25 x 17.125 (inner) | Plastic
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Steamline is a consistent favorite among Travel + Leisure editors for their vintage-inspired products ranging from trunk suitcases to stylish accessories. Their Editor Hatbox, in particular, is gorgeously made with a linen-wrapped exterior that’s accented by leather trim and silver hardware. The interior is draped with hand-painted prints; choose from moody palm tree motifs or colorful jungle scenes that feel reminiscent to the opening sequence of “The White Lotus.”
After testing this box thoroughly, we love that there’s substance behind the evocative designs. The hard shell and round shape kept our hats tightly packed and in their rightful place, and we were able to fit one to two hats (we tested the small hatbox, but the brand also offers a large size). There’s also a small pocket inside the lid, and even when packed full, we thought there was ample room to store a travel pouch, sweater, or scarf. Carry it either by the top grab handle or use the removable, adjustable strap, which can be positioned over the shoulder or worn crossbody.
The Details: Fits 1-2 hats | 12 x 11.25 x 4.5 inches (outer) and 11.25 x 10.5 x 4.25 inches (inner) | Linen, leather, and nickel-plated alloy
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Why We Love It
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The leather shell is durable, sturdy, and protective, and the extra-large size makes it extra-versatile.
Crafted from soft and supple pebbled leather, this hat box won us over with its high-quality materials and timeless retro-inspired round shape. The overall size is quite generous and, though the brand indicates it’s designed to fit around two hats, in our tests, we determined it could fit more than that. As such, it’s a smart choice for anyone who likes to travel with several pieces of headwear in tow.
Admittedly, it may be too big to fit underneath airplane seats, but would fit in overhead bins, and is TSA-approved for carry-on use. On that note, the exterior features a helpful trolley sleeve, so you may secure it to a suitcase handle, and it also has both a wristlet-style handle and a crossbody strap that’s adjustable and removable.
The Details: Fits 2+ hats, depending on size | 17 x 18.5 x 7 inches | Leather
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Why We Love It
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Lightweight and permissible as a carry-on, we were impressed by the travel-friendly features including a trolley sleeve, carrying strap, and passport pocket.
So far on this list, we’ve identified several standout options, but they all have the same drawback in common: their hard shape makes them unable to fold down to save space when not in use. If that’s a concern, we strongly suggest this option, which is lightweight, padded, and fully collapsible. It comes with rigid sidewall inserts that give the case structure and protection when in transit, but may be removed when not in use.
During our tests, we were able to stack and pack five cowboy hats on top of each other. We were also impressed by the interior adjustable elastic straps that kept all hats we tested in place, and appreciated a slew of features befitting frequent flyers. The carry-on approved bag also has a trolley sleeve that slips over a rolling luggage handle, a top handle and a removable shoulder strap, a zippered passport pocket, and additional space for accessory storage.
The Details: Fits 3+ hats, depending on size and nesting capability | 17.5 x 17.5 x 8 inches (built) and 17.5 x 17.5 x 3.5 inches (collapsed) | 3 pounds | Cotton canvas and polyester
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Sun-soaked destinations often call for a hat that captures a sense of tropical ease, be it a classic Panama or a floppy brim. And this raffia-wrapped hat box feels just as suited to the journey as the contents it’s meant to carry. The hard-shell design is finished with polished leather trim and has a detachable shoulder strap for a chic silhouette. We also think it could double as an overnight bag or keepsake box—making it a great option for both size and style.
During our tests, we were able to fit four sun and cowboy hats inside with different sized brims. We also liked that it has two interior pockets, including one large slip pocket on the lid and an additional zippered pouch. Because it’s so generously sized, we could throw in a few extra items like socks, travel pouches, and even a sweater when we packed fewer than four hats.
The Details: Fits up to 4 hats, depending on size | 18 x 16.5 x 6 inches | MDF, woven raffia, polyester, and polyurethane leather
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Why We Love It
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Designed to transport cowboy hats, it can also fit wide-brimmed, fedora, and Outback-style hats.
When western wear and only western wear is on the agenda, the very best bet is to go with a case designed specifically for that purpose. This well-priced box (that itself looks like a hat) is crush- and water-resistant with a molded design that’s intentionally fitted to keep cowboy-style hats looking pristine and dent free. We think you could probably fit a few hats inside depending on the size, but it’s meant to hold up to two cowboy hats and does an excellent job at that.
Structured, sturdy, and protective, it has dual elastic straps at the bottom to secure the hat or hats in place during travel with a heavy-duty zipper that won’t come open accidentally. We particularly liked that it has multiple carry options from the top rubber handle to the removable and adjustable straps, which may be worn as a backpack for a convenient option.
The Details: Fits up to 2 hats | 17.9 x 15.7 x 6.9 inches | 1650D Oxford fabric and EVA
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When transporting baseball hats, most large circular style cases can be overkill. At the same time, it wouldn’t be wise to just toss one into a suitcase unprotected, as that could result in creasing, dents, or damage to the brim. Instead, go with a case designed specially for baseball caps like the Ozueccr Hard Hat Travel Case, which we tested and love for its durability.
The hard shell is crush-, splash-, and dust-proof, with a soft-padded interior that can fit up to six hats. During testing, even when stacked full, nothing budged, and the case itself always felt lightweight, whether empty or at capacity. We also liked the smooth zippers, which are a breeze to open and close. The top handle grip and removable padded strap that’s adjustable and may be worn over one shoulder or crossbody adds to the case’s versatility, too.
The Details: Fits up to 6 hats | 12.6 x 9 x 6.1 inches | 1650D Oxford fabric and EVA
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Why We Love It
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A backpack, laptop case, and hat carrier in one, this innovative bag meets key traveler needs in a singular offering.
Upon first glance, this sleek backpack looks straightforward enough, but hidden inside the main compartment is an unexpected hat carrier. What appears to be a traditional backpack pocket is actually a custom molded shell with an interior tray meant to accommodate hats with brims up to 4.5-inches wide. In our tests, the rigid structure was able to prevent hats from becoming crushed or misshapen.
Additionally, behind the hat case is a zippered sleeve intended to hold a laptop or tablet. The combination of functions make this a standout choice for business travelers or anyone looking to maximize the use of their backpack. We also enjoyed using the interior pockets to stash headphones, a passport, or other small items, while an exterior water bottle pocket and trolley strap were useful while traveling. And for those with a sensitive back, the backpack straps can more evenly distribute weight than a typical shoulder-carry case.
The Details: Fits 1 hat | Denim
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This is the box we recommend for those who adore the statement-making style of a round vintage-style case, but prefer a softside shell that’s easier to store. The exterior shell has a plush, padded construction, made with a coated polyester material that’s water- and damage-resistant. Rigid removable inserts provide structure around the sides, and even without a hard case, we thought the top and bottom were plenty durable.
During our tests, everything from the materials to the hardware struck us as substantial, and we thought the interior was sufficiently spacious. While the specifications indicate it’s meant to fit two to three hats, we were able to fit five stacked hats or one tall hat with a wide brim. The design also features a trolley sleeve, adjustable shoulder strap, a top handle, and interior pockets meant to hold hat bands, pins, and other accessories.
The Details: Fits up to 5 hats | 18.5 x 17.5 x 8 inches | Tarpaulin-coated polyester and polyester
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Highly versatile, this hat case offers full protection on the go, or may be used as a storage container for hats or other items when not in use. We used it to store hats free of dust, and even to keep piles of sweaters, towels, toys, or blankets tucked away inside. A clear window makes it easy to quickly identify the contents if you use it this way. It can also be folded away entirely. The circular upright shape is maintained by inserting four rods into the walls. When removed, the case is completely collapsible.
When we used it as a travel hat box, we thought the two interior elastic bands kept headwear in place well, and liked how the wide handle doubles as a suitcase trolley sleeve. During our testing period, we were able to stack at least four hats on top of each other. Place smaller hats inside, and you might even fit up to 10.
The Details: Fits up to 10 hats | 16 x 15 x 8 inches (open) and 16 x 15 x 1.5 inches (collapsed) | Waterproof fabric
Our Testing Process
We tested 10 hat boxes and will continue to test even more, evaluating each for ease of use, protection, capacity, portability, and value. As part of our tests, we packed and traveled with each hat box, filling each to the brim—pun intended—to ensure it could fit the number of hats promised, and that all hats left the box looking as pristine as when they entered.
We also tested every case with numerous styles from floppy sun hats to baseball caps, fedoras and straw hats, western varieties, and more to ensure that each case was reliable regardless of shape. Cases were then closely analyzed to examine how easy or intuitive they were to open and close, and all features, such as elastic straps or adjustable buckles, were thoroughly tested to evaluate their functionality.
To properly protect all hats, we chose cases made from sturdy, durable, and protective materials in order to ensure none would become crushed or misshapen during travel, and that they were adequately sized to protect hat brims and crowns without issue. The best hat cases we chose are comfortable to hold with multiple carry options, and some come with organizational features that add value, with sleek profiles that are free of extraneous bulk. We will continue using these cases for the next six months to collect further insights.
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Tips for Buying a Hat Box
Look for special features
Once you know you have the material, size, and shape you need in a hat box, it’s wise to consider additional features that might prove useful. For example, some of our favorite cases come with internal elastic straps that secure hats in place and keep them from jostling around. This can be a key consideration if your hat is delicate or dents easily, or if you have multiple hats in your arsenal and don’t want to arrive at your destination to find them jumbled in one messy heap.
And since you’ll be traveling with what is essentially an extra carry-on, it’s smart to look for a box with built-in organization elements such as internal pockets so you can maximize space and pare down the number of bags you’ll need. Some cases come with unique extras like mirrors, luggage trolley sleeves, or removable straps, which could come in handy depending on your trip and what might prove most beneficial to you in making it smoother and easier.
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Determine the best size and shape for your needs
When buying a travel hat box, it’s important to first consider the type, size, number, and shape of the hats you own or plan to purchase. You’ll want to make sure to choose a box that best accommodates those individual hats. For example, think about the number of hats you plan to pack and look for a case that can fit that many. Additionally, don’t purchase a hat case without first measuring your largest, widest headpieces to make sure they will fit inside your intended box.
We also suggest thinking about how you prefer to carry a case: do you want to pack it inside a checked suitcase, or will you tote it as a carry-on item? If it’s the latter, look for cases with an adjustable or removable shoulder strap, in addition to top carry handles, for multiple transportation options. These considerations will help steer you to the best travel hat box for you.
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Choose the proper material
It’s also important to consider the material your hat box is made from as it can affect the hat inside. For example, if you have a fedora with a delicate crown or a baseball cap with a perfectly flat brim you want to maintain, you’ll want to choose a hard case where the hat profile can’t be easily crushed. A floppy hat, however, might do just fine in a softside case, which can also typically be repurposed more easily as general storage.
On the flip side, hardside cases will be heavier to carry, and some may need to be checked as luggage if they are especially large. You should also factor in features such as padding or water protection for especially fragile headwear to ensure no damage ensues during travel.
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Frequently Asked Questions
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How many hats can I realistically fit into one hat box?
While a box might proudly advertise it can fit anywhere from five to 15 hats, the reality might not exactly match up if your hats are oversized, bulky, or don’t stack well. The number of hats you fit inside a travel case will ultimately depend on the size and dimensions of the box and how well each hat nestles inside.
If you’re concerned, be sure to measure your hats before buying the box to confirm they will fit, and look for boxes with flexible return policies, so you can safely try it out at home with all of your hats.
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Are hat boxes considered a personal item on flights?
It depends on the airline: like any other carry-on or personal item brought onboard a flight, a hat box will need to meet that individual airline’s dimension requirements. Typically, a personal item needs to fit underneath the seat in front of you without sticking out. Hat boxes that are designed to carry oversized and wide-brim hats may be too large for such a setting.
In those instances, an airline may count it as an overhead carry-on or require you to check it for the duration of the flight. It’s best to be prepared for these scenarios by knowing the measurements of your individual box and understanding the specific airline’s policy for cabin luggage so there are no last-minute surprises.
Why Trust Travel + Leisure
Emily Hochberg is an experienced travel and lifestyle writer and editor who vacations frequently with her family and regularly brings a sun hat and visor. As such, she has first-hand experience with the methods that do and don’t work well when transporting hats. For this article, she utilized in-depth insights and analysis from tests conducted on each item to share the very best options for traveling with all types of hats.
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