Keeping your hair and head protected when welding is paramount if you want to stay safe. Nobody wants singed hair, or worse. The damage from sparks and spatters can be devastating.
We look at the 7 best welding caps to give you the information to keep you safe.
- 8 panels
- Cotton duck canvas
- Protective flap
- Sweat-absorbent
- Machine-washable
- Flame-retardant
- Flame-retardant
- Lightweight
- Plenty of designs to choose from
- Beanie hat
- Weighs 0.64 oz
- One size fits all
- 6-panel reversible cap
- Weighs 1.6 ounces
- Sizes 7 to 8
- 100 percent cotton
- Sweat absorbent liner
- Comes with elastic headband
- Double-layered
- Wide brim
- Full-crown shape
Review Methodology: At Sensible Digs, we believe in delivering trustworthy, hands-on analysis of products to our readers. Our experienced team conducts thorough research, using stringent criteria and benchmarks to evaluate the best welding caps available in the market. We compare and score these products based on key decision-making factors such as durability, comfort, design, and safety. Our professional assessments are backed by quantitative data and first-hand experience, providing clear evidence of each product’s performance. We aim to help you make informed decisions by highlighting what sets these welding caps apart from their competitors. Rest assured, our reviews and recommendations are always based on facts and results, providing you with the most reliable guide to the best welding caps.
The Best Welding Caps of 2024
Welding caps come in all designs and styles, so finding the best 7 was a challenge. Here are the 7 best welding caps we could find.
Welder Nation 8-Panel Welding Cap
Best Fitting Welding Cap
This Welder Nation cap has 8 panels, just like the traditional welding caps, which means it fits snugly to the contours of your head.
This cap is constructed from durable 10-ounce cotton duck canvas, so it is lightweight, breathable and comfortable to wear.
The inner lining is cotton, it has a small flap that protects your eyes, neck and ears, and it is suitable for stick and MIG welding.
Pros
- 8 panels.
- Cotton duck canvas.
- Protective flap.
- Lightweight.
Cons
- Large sizes.
Product Specs
| Weight (ounces) | 2.4 |
| Dimensions (inches) | 11.22 x 7 x 0.5 |
| Material | Cotton duck canvas |
| Flap | Yes |
| Sizes | 6.875 to 8 |
| Cost | $$$ |
Our Ratings
User Experience
Lincoln Electric KH823L Flame-Resistant Cap
Best Budget Welding Cap
This is a beanie-style hat that sits under a welding helmet and increases the comfort for the wearer. It is also flame-retardant, which means it protects against sparks, flames and spatters of molten metal.
It is made from cotton, making it breathable and lightweight, at just 9 ounces, and is machine-washable as well as super absorbent for sweat, which helps when you are working in a hot environment all day.
This cap stands out thanks to the price-tag. It retails at a fraction of some on the list, making it incredible value for money.
Pros
- Lightweight.
- Sweat-absorbent.
- Machine-washable.
- Flame-retardant.
- Incredible value for money.
Cons
- No protective flaps.
- Only protects the scalp.
Product Specs
| Weight (ounces) | 9 |
| Dimensions (inches) | 11 x 6 x 1 |
| Material | Cotton |
| Flap | No |
| Sizes | Large |
| Cost | $ |
Our Ratings
Personal Perspective
Riverweld Fashionable Flame-Retardant Welding Cap
Best Flame-Retardant Welding Cap
This has caught my attention not only because of the design but also by how many people actually loved it. This cap repels flames and sparks with ease. It has a lacing back and is made of cotton thus it is comfortable to wear. In fact, you can easily pair it with a welding helmet for added protection.
It weighs just 2.82 ounces and comes with 11 colors to choose from. This cap is better suited as additional protection beneath the welding helmet.
Pros
- Flame-retardant.
- Lightweight.
- Affordable.
- Plenty of designs.
Cons
- Thin fabric.
- Size runs small.
Product Specs
| Weight (ounces) | 2.82 |
| Dimensions (inches) | 5.91 x 7.09 x 3.54 |
| Material | Cotton |
| Flap | Yes |
| Sizes | Not specified |
| Cost | $ |
Our Ratings
Community Feedback
BSX Gear BC5B-BK Welding Beanie
Best Beanie Welding Cap
This beanie hat is a one size fits all, so it should make sizing it easy. It is made from flame-retardant cotton and is suitable for all welding applications. Like the other beanie hats featured, it doesn’t offer the same level of protection for your eyes and ears, but it does fit snugly beneath your welding helmet to increase the comfort levels.
The cap is breathable, and the sizing is on the large size, so when you wash it, watch for shrinkage. And, weighing just 0.64 ounces means this cap is super-light, so you won’t even know you have it on.
Pros
- Flame-retardant.
- Weighs 0.64 ounces.
- One size fits all.
- Great brand name.
Cons
- Only protects the scalp.
- Prone to shrinkage.
Product Specs
| Weight (ounces) | 0.64 |
| Dimensions (inches) | 9 x 6 x 1 |
| Material | Cotton |
| Flap | No |
| Sizes | One size fits all |
| Cost | $ |
Our Ratings
First-Hand Impression
Comeaux 118-2000-C Camouflage Welding Cap
Best Welding Cap with Style
This is a 6-panel reversible cap made of cotton. It has a soft flap that protects the eyes and ears from spatters, and if you flip it around, it covers the neck. It is a deep round-crown cap, designed to sit low on the welder’s head to cover the tops of their ears.
This particular cap has reinforced stitching and comes in a fashionable camouflage design. Other colors are available, as well as sizes ranging from 7 to 8.
Pros
- Flame-retardant.
- Weighs 1.6 ounces.
- Sizes 7 to 8.
- Great brand name.
Cons
- Large sizes.
Product Specs
| Weight (ounces) | 1.6 |
| Dimensions (inches) | 10 x 6.75 x 1.25 |
| Material | Cotton |
| Flap | Yes |
| Sizes | 7 to 8 |
| Cost | $ |
Our Ratings
User Experience
Lincoln Electric Welding Cap
Best Custom Welding Cap
If you are looking for a welding cap that taps into your patriotism, this is the hat for you. It comes with a stars and stripes design that should suit almost everyone’s taste. It is 100 percent cotton with a cotton thread.
It also has a sweat-absorbent liner that keeps your head dry no matter what the conditions and the flap protects both your eyes and ears from spatters and sparks. It is a one size fits all, with an elastic headband that makes fitting and wearing this cap super-comfortable.
Pros
- Flame-retardant.
- One size fits all.
- Elasticated.
- Sweat absorbent liner.
- Great brand name.
Cons
- Tight fit.
Product Specs
| Weight (ounces) | 1.12 |
| Dimensions (inches) | 6 x 1 x 1 |
| Material | Cotton |
| Flap | Yes |
| Sizes | One size fits all |
| Cost | $ |
Our Ratings
Personal Perspective
Revco BC5W-BK Armor Welding Cap
Best Sweat-Absorbing Welding Cap
This Revco cap is double-layered for extra protection. It keeps your head cool, absorbing sweat, thanks to the breathable 100 percent cotton material, and the elasticated headband makes it easy to adjust the cap to fit your head. It also holds it in place, securing your hair under the elasticated band to protect it.
This cap also has a full brim, so it increases the protection you get for your eyes and ears, and the full-crown shape naturally sits low on your head for increased security.
Pros
- Flame-retardant.
- One size fits all.
- Elasticated.
- 100 percent cotton.
- Wide brim.
Cons
- Tight fit.
- No returns policy.
Product Specs
| Weight (ounces) | 2.24 |
| Dimensions (inches) | 5 x 4 x 1 |
| Material | Cotton |
| Flap | Yes |
| Sizes | One size fits all |
| Cost | $ |
Our Ratings
Community Feedback
| Product | Best | Weight | Dimensions | Material | Flap | Sizes |
|---|---|---|---|---|---|---|
| Welder NationWelding Cap | Good Fit | 2.4 oz | 11.22 x 7 x 0.5″ | Cotton | Yes | 6.875 to 8 |
| Lincoln Electric Flame-Resistant Cap | Budget Pick | 9 oz | 11 x 6 x 1″ | Cotton | No | Large |
| Riverweld Welding Beanie | Flame-Retardant | 2.82 oz | 5.91 x 7.09 x 3.54″ | Cotton | Yes | N/A |
| BSX Gear BC5B-BK Welding Beanie | Beanie | 0.64 oz | 9 x 6 x 1″ | Cotton | No | One size |
| Comeaux Camouflage Welding Cap | Style | 2 oz | 10 x 6.75 x 1.25″ | Cotton | Yes | 7 to 8 |
| Lincoln Electric Welding Cap | Customized | 1 oz | 6 x 1 x 1″ | Cotton | Yes | One size |
| Revco BC5W-BK Armor Welding Cap | Sweat-Absorbing | 2.24 oz | 5 x 4 x 1″ | Cotton | Yes | One size |
Why Do Welders Wear Welding Caps?
The simple answer is to keep their scalp, eyes, ears and neck safe from burns, spatters and fire damage. Welding is hot and dangerous work, and when you are working at close quarters, concentrating on completing your project, your head will be close to the weld pool.
Plus, there is also the risk of radiation and UV damage caused by the welding machine. UV is very bad for the skin, and overexposure can lead to skin cancers.
How To Choose the Best Welding Cap
Choosing a welding cap is not as simple as just finding a design you like. It needs to be comfortable, flexible, and suitable for the welding jobs you do. Here are some of the fundamentals to bear in mind when shopping for a welding cap.
Think Fabric
Welding caps need to be comfortable. They can’t be itchy or scratchy. When working in a hot environment all day, the cap needs to be as comfortable to wear at the end of the working day as at the start.
Cotton is the most common material used in welding cap construction. It is soft to the touch and repels sparks easily, especially if it is non-flammable cotton. Avoid anything nylon, as it is not flame-retardant.
Think Flap and Coverage
Not all welding caps have a flap to protect your eyes, ears and neck. Some are like beanie hats that sit under your welding helmet to make it more comfortable. If you are relying on the cap for added protection, get one with a flap that can protect your eyes, and if needed, can flip around and protect your neck.
Think Durability
Welding caps need to be robust enough to repel sparks. They also need to withstand the rigors of everyday welding tasks. The last thing you want is a cap that burns through on the first attempt. The thickness of the fabric and the quality of the threads all play their part in this success.
Think Style
You might want a particular design on your welding cap or something that resembles a baseball cap, more akin to everyday wear. While style is arguably the least important aspect, there is no law that says you can’t look good while wearing one.
Think Flexibility
Welding caps should perform no matter what the circumstances. If you are overhead welding and need side protection, your welding cap should be flippable to protect the side of your head nearest the weld line.
Likewise, the welding technique you do is also important when choosing a weld cap. TIG welding may spatter less, but it still sparks, and the heat generated is greater than other methods. MIG and stick welding is messy and calls for the extra protection offered by a welding cap.
Think Panels
The more panels a welding cap has, the better it conforms to the shape of your head. Caps were originally stitched together from old cut-offs of material, and so the multi-panel look was born. Even the commercially-produced caps resemble the traditional look.
Welding Cap FAQs
What Size Welding Cap Do I Need?
Here’s a handy chart:
| Cap Size (Inches) | Head Measurement (Inches) |
| 7.0 | 22 |
| 7.13 | 22.50 |
| 7.25 | 23 |
| 7.38 | 23.25 |
| 7.50 | 23.75 |
| 7.75 | 24.50 |
What Fabric Is Used for Welding Caps?
Cotton is the most widely used fabric because it is breathable, soft, and excellent at heat and flame retardedness. The thread should also be cotton.
How Do You Wear a Welding Cap?
You can wear it in several ways. With the flap to the front, it protects your eyes, and on the side, it keeps your ears safe. Flip the cap around, and the flap now protects your neck.
Are Welding Caps Supposed to Be Tight?
Welding caps should be tightened to set in place when welding but not too tight as they may cause discomfort. According to Comeaux, it’s best to measure your head before purchasing a welding cap.
The measuring process is simple as it only requires some fabric tape measure. Place the tape’s end at the center of your forehead.
Stretch it along the neck’s nape, returning to the starting point. Manufacturers typically offer a sizing chart that allows you to pick the best cap for your head size based on your measurements.
How Do You Stretch a Welding Cap?
The best way to stretch a welding cap is to apply heat to the material. Welders often use a hair dryer for the process. This makes the material more flexible, but overheating the cap may damage it.
Why Do Welders Wear Caps Sideways?
Welders wear their caps sideways for two main reasons. The first common reason is their working position.
When you have to weld in an unusual position, the cap can sometimes get in the way, and keeping it sideways can prevent that. When you wear your welding cap sideways, you can protect your ears from flames and heat.
Where Are Comeaux Welding Caps Made?
Comeaux welding caps are made right here in the United States. The company is based in Louisiana and makes a wide range of welding and industrial headwear, including caps, beanies, and even bandanas.
Their stuff is made with high-quality materials designed to provide comfort and protection for welders, industrial workers, and other tradespeople.
If the Cap Fits
You cannot put a price on welding safety, and a welding cap should be part of every welder’s protective equipment. When you are working at close quarters with the weld line, keeping the vulnerable bits of your body safe is a top priority.
Welding caps also increase the comfort levels of the welding helmet, making for a better experience for the welder.
