Facebook

Best Welding Caps of 2021

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

Real Talk: Sensible Digs earns a commission through the following independently chosen links at no additional cost to you.
Image
Model
Product Comparison Table
Features
Product Image of the Welder Nation – 8 Panel Welding Cap, Durable, Soft 10 oz Cotton Duck Canvas, for Safety and Protection While Welding. Stick ARC (7 1/4, White, Black)
Best Fitting Welding Cap
Welder NationWelding Cap
  • 8 panels
  • Cotton duck canvas
  • Protective flap
Product Image of the Lincoln Electric KH823L Black Large Flame-Resistant Welding Beanie
Best Budget Welding Cap
Lincoln Electric Flame-Resistant Cap
  • Sweat-absorbent
  • Machine-washable
  • Flame-retardant
Product Image of the Lincoln Electric Welding Beanie | Flame Resistant (FR) | Black & Red | Large |K2994-L
Best Flame-Retardant Welding Cap
Lincoln Electric FR Welding Beanie
  • Flame-retardant
  • Lightweight
  • Reinforced seams
Product Image of the BSX Gear BC5B-BK Welding Beanie One Size Fits Most, Black
Best Beanie Welding Cap
BSX Gear BC5B-BK Welding Beanie
  • Beanie hat
  • Weighs 0.64 oz
  • One size fits all
Product Image of the Comeaux Caps 118-2000-C-7-5/8 Deep Round Crown Caps, 7 5/8', Camouflage
Best Style
Comeaux Camouflage Welding Cap
  • 6-panel reversible cap
  • Weighs 1.6 ounces
  • Sizes 7 to 8
Product Image of the Lincoln Electric Welding Cap| Mesh Inside Liner | All American Print |K3203-ALL
Best Custom Welding Cap
Lincoln Electric Welding Cap
  • 100 percent cotton
  • Sweat absorbent liner
  • Comes with elastic headband
Product Image of the Revco REVCO - BC5W-BK Armor Cotton Welding Cap, 100% Cotton Double Layer Protection
Best Sweat-Absorbing Welding Cap
Revco BC5W-BK Armor Welding Cap
  • Double-layered
  • Wide brim
  • Full-crown shape

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.


The Best Welding Caps of 2021

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.

1. 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.

Additional Specs

Weight (ounces) 10
Dimensions (inches) 11.5 x 4 x 1.1
Material Cotton duck canvas
Flap Yes
Sizes 7.25 to 8
Cost $$$

2. 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.

Additional Specs

Weight (ounces) 9
Dimensions (inches) 11 x 6 x 1
Material Cotton
Flap No
Sizes Large
Cost $

3. Lincoln Electric FR Welding Beanie

Best Flame-Retardant Welding Cap

This is the second Lincoln Electric beanie cap to feature in the review. Like the other one, this cap repels flames and sparks with ease. It is a beanie, so it doesn’t offer the same face and ear protection that welding caps with flaps do, but it does have a moisture-wicking anti-static and mildew coating.

It weighs just 9 ounces and comes with high-strength seams to stop the hat from falling apart. It also means the cap can take the punishing environment that welders work in. This cap is better suited as additional protection beneath the welding helmet.

Pros

  • Flame-retardant.
  • Lightweight.
  • Reinforced seams.
  • Great brand name.

Cons

  • No protective flaps.
  • Only protects the scalp.

Additional Specs

Weight (ounces) 9
Dimensions (inches) 11 x 6 x 1
Material Cotton
Flap No
Sizes 7 to 7.25
Cost $

4. 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.

Additional Specs

Weight (ounces) 0.64
Dimensions (inches) 9 x 6 x 1
Material Cotton
Flap No
Sizes One size fits all
Cost $

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.

Additional Specs

Weight (ounces) 1.6
Dimensions (inches) 10 x 6.75 x 1.25
Material Cotton
Flap Yes
Sizes 7 to 8
Cost $

6. 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.

Additional Specs

Weight (ounces) 1.12
Dimensions (inches) 6 x 1 x 1
Material Cotton
Flap Yes
Sizes One size fits all
Cost $

7. 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.

Additional Specs

Weight (ounces) 2.24
Dimensions (inches) 5 x 4 x 1
Material Cotton
Flap Yes
Sizes One size fits all
Cost $

Welding Cap Comparison Chart

Product Best Weight Dimensions Material Flap Sizes
Welder NationWelding Cap Good Fit 10 oz 11.5 x 4 x 1.1″ Cotton Yes 7.25 to 8
Lincoln Electric Flame-Resistant Cap Budget Pick 9 oz 11 x 6 x 1″ Cotton No Large
Lincoln Electric FR Welding Beanie Flame-Retardant 9 oz 11 x 6 x 1″ Cotton No 7 to 7.25
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

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.


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.

Headshot of Mark Weir

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.

Leave a Comment