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7 Best Welding Caps of 2024

Updated
Welding caps keep your head safe.

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.

Our Top Picks

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Best Fitting Welding Cap : Welder NationWelding Cap
  • 8 panels
  • Cotton duck canvas
  • Protective flap
Best Budget Welding Cap: Lincoln Electric Flame-Resistant Cap
  • Sweat-absorbent
  • Machine-washable
  • Flame-retardant
Best Flame-Retardant Welding Cap: Riverweld Welding Cap
  • Flame-retardant
  • Lightweight
  • Plenty of designs to choose from
Best Beanie Welding Cap: BSX Gear BC5B-BK Welding Beanie
  • Beanie hat
  • Weighs 0.64 oz
  • One size fits all
Best Style: Comeaux Camouflage Welding Cap
  • 6-panel reversible cap
  • Weighs 1.6 ounces
  • Sizes 7 to 8
Best Custom Welding Cap: Lincoln Electric Welding Cap
  • 100 percent cotton
  • Sweat absorbent liner
  • Comes with elastic headband
Best Sweat-Absorbing Welding Cap: Revco BC5W-BK Armor Welding Cap
  • Double-layered
  • Wide brim
  • Full-crown shape


Product Reviews

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

Protection
4.5 / 5
Comfort
4.5 / 5
Material Quality
4.5 / 5
Durability
4.5 / 5
Total Rating
4.5 / 5

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

Protection
3.5 / 5
Comfort
4.5 / 5
Material Quality
4 / 5
Durability
4 / 5
Total Rating
4 / 5

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

Protection
3.5 / 5
Comfort
4 / 5
Material Quality
3.5 / 5
Durability
3.5 / 5
Total Rating
3.5 / 5

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

Protection
3 / 5
Comfort
4.5 / 5
Material Quality
4 / 5
Durability
4 / 5
Total Rating
3.75 / 5

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

Protection
4 / 5
Comfort
4 / 5
Material Quality
4 / 5
Durability
4 / 5
Total Rating
4 / 5

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

Protection
4 / 5
Comfort
4.5 / 5
Material Quality
4.5 / 5
Durability
4 / 5
Total Rating
4.25 / 5

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

Protection
4 / 5
Comfort
4 / 5
Material Quality
4 / 5
Durability
4 / 5
Total Rating
4 / 5

Product Comparison Chart

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.

Factors to Keep in Mind

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.

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About the Author

Mark Weir

Mark spent 24 years working in real estate, so he knows his way around a home. He also worked with contractors and experts, advising them on issues of planning, investments, and renovations. Mark is no stranger to hands-on experience, having renovated his own home and many properties for resale. He likes nothing better than seeing a project through to completion.