There are different types of headwear to use for the safety and protection of your hair and scalp while welding. But if you’re looking for something stylish and comfortable to wear for long hours, look no further than the best welding caps.
This headwear will protect your head and hair from spatters, flames, sparks, and heat in hot working conditions.
But shopping for the best welder caps from thousands of options isn’t always easy.
Relax!
In this welding cap review, I gonna recommend some of the best choices that will help you keep safe and comfortable.
Rather than investing your valuable bucks on the fancy caps (that are good for nothing), you can try any of these my recommended caps.
Rest assured, these headwears will give you maximum safety at a reasonable price.
10 Top- rated Welding Caps- Quick Comparison Chart
If you’re in a hurry, the following chart will help you to compare all the choices quickly for making a wise buying decision.
Product Name | Material | Gender | Size (Inches) | Price |
  Welder Nation Welding Cap | 10 oz. cotton | Unisex-adult | Various | |
  Comeaux Welding Caps | 100% cotton | Male | Various | |
  Revco REVCO - BC5W-BK Armor | 100% cotton | Unisex-adult | One-size-fits-most | |
  Fullsheild FR Welding Cap HRC2 | 100% cotton | Unisex-adult | One-size-fits-most | |
  Ergodyne - 12478 Doo Rag | High-quality moisture management fabric | Male | One-size-fits-most | |
  Lincoln Electric Welding Cap, K3203-ALL | 100% cotton | Unisex-adult | One-size-fits-most | |
  Lincoln Electric KH823L Welding Beanie | 9-ounce cotton, Flame-resistant | Unisex-adult | Various | |
  RIVERWELD Pure Cotton Welding cap | 100% cotton | Unisex-adult | One-size-fits-most | |
  Lincoln Electric K3204-ALL Welding Doo Rag | 100% cotton | Male | One-size-fits-most | |
  LAPCO LAP CC-7 1/4 Welder’s Cap | 100% cotton, Non FR | Male | Various |
Best Welding Caps- 10 Top Picks & Reviews
Welder’s caps are available in different sizes, shapes, designs, materials, and prices. Dozens of brands and manufacturers are hosting their products on the market. But not all are of good quality.
After extensive research, I’ve shortlisted the following 10 welders’ favorite caps that everyone can use. I hope my review will help you find the best and right one.
#1 Welder Nation Welding Cap – Best Overall
Specs
- Material: 100% Cotton (inside), duck canvas (exterior)
- Size: 6-7/8, 7, 7-1/2, 7-1/4, 7-1/8, 7-3/4, 7-3/8, 7-5/8, 7-7/8, 8
- Style: Unisex-adult
- Color: Ranch tan/ Olive (Available in more colors)
If you’re looking for a heavy-duty cotton welder cap, the Welder Nation 8 panel is this. It is a top-notch quality welding cap designed to withstand extreme working conditions.
Why Choose Welder Nation 8 Panel Welding Cap?
10 oz. cotton duck canvas exterior
This makes the cap very durable and stands up to extreme working conditions. But it’s very soft to wear comfortably for a long time. Thanks to its comfortable lined inside.
Soft brim
The brim on this welding cap is made of soft materials, but it is stiff enough to stay flipped up if you want.
Innovative 8-panel pattern design
The 7.5 inches high crown offers an exceptional fit. No unicorn peak on the top of the head!
Many options in sizes and colors
Welder Nation 8 Panel cap is available in six colors and ten different sizes, ranging from size 6-7/8 inches to 8 inches.
Pros
- Made of high-quality materials
- Very well-made
- Heavy-duty and durable
- Safe and comfortable
- Unique 8-panel design for the perfect fit
Cons
- Somewhat expensive, but worth the extra money for the quality and protection you get.
#2 Comeaux Caps Reversible Welding Cap
Specs
- Material: 100% cotton
- Size: 6-7/8, 7, 7.5, 7.25, 7-1/8, 7-3/4, 7-5/8, 7-7/8
- Gender: Male
- Color: Gray
You’ll love the Comeaux welding hat for its unique design.
Why Choose the Comeaux Welding cap?
Reversible design
This headwear is reversible with solid gray color on both sides. The cap and its brim/visor are sewn in such a way that the stitches are not visible either way.
Six-panel pattern
This 6-panel medium and round crowned cap will cover your ears and neck. It measures 7.25 inches from the top of the crown to the bottom of the hat. It is excellent for look and fit.
100% cotton construction
The 100% cotton materials and super soft brim make this headwear comfortable to wear a long time.
Pros
- Rugged construction
- Comfortable to wear
- Well-made
- Available in different sizes
Cons
- No issues found
#3 Revco Armor, BC5W-BK- Best Cotton Welding Cap (Best Overall)
Specs
- Material: 100% cotton
- Size: One-size fit-all
- Gender: Unisex-adult
The REVCO BC5W-BK is a 3-in-1 headwear for welders that you can use as a welding cap, doo rag, and beanie. In terms of materials and protection, it is second to none.
Why Choose Revco Armor Cotton Welding Cap?
100% cotton construction
It is comfortable and lightweight to use for a long time. The fabric is breathable, keeping you cool and comfortable in high-temperature welding areas.
Double layer protection
Revco Armor welding cap is thick to protect your hair from damage by flames and heat. Moreover, it is resistant to flames and won’t burn easily.
It fits most head sizes.
It comes in one size that fits most head sizes. There are elastic bands on the sides to conform to different size heads. So, you don’t need to attach any bands.
Full brim design
This cap is perfect to wear in and around any welding site. The full brim design is flexible to protect your eyes from welding sparks and dust.
Stylish design
Finally, this cotton cap lets you make an unusual fashion statement.
Pros
- Lightweight and very comfortable
- Super stylish
- Double layer protection
- Stretchable to fit any head size
- Resistant to flame
Cons
- Tight on the head of above-average circumference.
#4 Fullsheild FR Welding Cap HRC2- Best Fire Retardant Welding Cap
Specs
- Material: 100% cotton
- Size: One-size fit-all
- Gender: Unisex-adult
- Color: Available in 4 colors
You can use Fullsheild FR Welding Cap not only at work but also in daily life.
Why Choose Fullsheild FR Welding Cap?
100% flame retardant
This cap is made of the same fabric as FR jackets, shirts and coveralls. The material is self-extinguished or resists ignition. That means it’ll burn in case of fire but will automatically extinguish within two seconds after leaving the fire. Moreover, after burning, it’ll not drip and dissolve and won’t cause secondary damage to the body.
Reversible and both sides FR
The best part of this cap is that both sides are flame retardant. The double-layer construction offers extra protection.
Complies with USA & CANADA FLAME RESISTANT STANDARD
Fullsheild Welding Cap complies with NFPA 2112 for Flash Fire and NFPA 70E for Arc Flash. Its arc flash rating is 12 Cal/cm2 + 12 Cal/cm2.
2 Ply SOFT cotton structure
This flame retardant cap is comfortable to wear all day long. It is perfect to use as an inner lining for a welding helmet, welding hood or by itself.
One size fits all
With elastic, the size is adjustable, so it also fits comfortably on the big head. It is also available in both low crown and high crown designs. Low crown is perfect for a traditional fit, and a high crown for an over-the-ear fit.
Pros
- More Panels and elastic for Snug fit
- Comfortable to wear all day long
- Reversible and flame Resistant (both sides)
- Stretchy, so it fits most heads
- Available in four colors and low & high crown design
- Designed in the USA
Cons
- Initially, it may feel tight to the big head, but it’ll be more comfortable over time.
#5 Ergodyne – 12478 Chill Its 6615 Dew Rag
Specs
- Material: High-quality moisture management fabric
- Size: One size fits all
- Gender: Male
- Color: Various
The Ergodyne 6615 is a high-Performance Doo Rag that will sop up your sweat with style.
Why Choose Ergodyne Doo Rag?
Made with Hi Cool moisture-wicking technology
The high-quality breathable and moisture management fabric absorbs sweat for all-day comfortable uses. The terry cloth sweatband prevents sweat from dripping into your eyes and keeps you comfortable.
One size fits most
This doo rag is designed to adjust to your desired fit easily. There is an elastic band at the back to stretch to fit various head sizes.
Low profile design
It is lightweight and low-profile, which makes it comfortable to wear under helmets, hard hats, or by itself. It is one of the best headwear for roofing, landscaping, construction or anyone working in the heat. It’s also excellent for hiking, running and other recreational activities.
Pros
- Super absorbent and quick-drying
- Machine washable
- Reusable and durable
- Low-profile design
- Available in different colors and patterns
- Reasonable price
Cons
- Too small for man’s big head
#6 Lincoln Electric Welding Cap, K3203-ALL
Specs
- Material: 100% cotton
- Size: One-size fit-all
- Gender: Unisex-adult
Lincoln Electric stars and stripes pattern is an all-American welder cap used by professional fabricators daily. The Stars and stripes fabric pattern adds a stylish appearance to this cap.
Why Choose Lincoln Electric K3203-ALL?
100% cotton fabric
Lightweight and breathable fabric allow two-way airflow to keep your head cool.
Athletic mesh liner
Sweat absorbent athletic mesh liner absorbs sweat and improves comfort for long-term use. The high crown design also aids ventilation.
Flat stitching seam patterns
These well-stitched patterns prevent discomfort from seams contacting the skin and enhance the durability of the cap.
Padded elastic headband
It provides superior comfort and a snug fit for various head sizes (one size fits all).
Pros
- Well-made and heavy-duty
- Breathable and lightweight
- Maximum sweat absorbency
- Flat-stitched for superior comfort
- Snug fit for most head sizes
- Machine wash recommended
Cons
- If your head is 7-1/2 or bigger, it won’t fit.
#7 Lincoln Electric KH823L Flame-Resistant Welding Beanie
Specs
- Material: 9-ounce cotton
- Size: One-size fit-all
- Gender: Unisex-adult
- Color: Black, CF2929
The Lincoln Electric KH823L is an incredibly low-priced, flame-resistant welding Beanie available.
Why Choose Lincoln Electric Beanie?
Flame Retardant Materials
The 9-ounce flame-retardant fabric construction protects your head from welding sparks and heat.
Cushioned inner
It’s made of breathable fabric, so your head will not sweat nearly as badly as possible. The cushioned inner makes it comfortable to wear under your welding helmet or welding hood.
Pros
- Breathable and comfortable
- Flame-resistant
- Well-made and durable
- Machine washable for easy cleaning
- Available in an L size (fits hat size 7 to 7-3/8) and XL size (fits hat size 7-3/8 to 7-3/4)
It comes with extremely budget-friendly price
Cons
- Basic cap
#8 RIVERWELD Fashion Style Pure Cotton Welding Cap
Specs
- Materials: 100% cotton
- Size: One size fits most
- Gender: Unisex-adult
The RIVERWELD is a beautiful American-style welding cap that protects your head from spatter or flames flying around during welding.
Why Choose RIVERWELD Welding Cap?
- It’s designed with all-cotton to give you a high level of comfort and a nice feeling. It covers ears and neck from those random sparks.
- It matches with any welding helmet.
- Washable for easy cleanup
- This cap comes with competitive pricing.
Pros
- Wonderful American style
- Nicely made
- Very comfortable to wear
Cons
- The elastic headband makes it somewhat uncomfortable.
#9 Lincoln Electric K3204-ALL– Best Skull Cap
Specs
- Material: 100% cotton
- Size: One size fits all
- Gender: Male
- Color: stars and stripes fabric pattern
Lincoln Electric K3204-ALL is a very lightweight and comfortable skull cap. It protects the top of your head and helps keep you cool.
Why Choose Lincoln Electric Skull Cap?
Made from high thread count cotton
The breathable high-quality cotton fabric construction allows two-way airflow and keeps your head cool.
Sweat absorbent inner mesh liner
It improves comfort by absorbing moisture. It also helps prevent hair pulling. It keeps the sweat off your head if you use it under a welding shield or hard hat.
Tie closure system
It features a tie closure system in the back, so it is always a snug fit. Plus, it matches the All-American TM helmet.
Looks cool
The stylish stars and stripes fabric pattern (All American Print) looks fantastic.
Pros
- High-quality construction
- Trusted by professional
- One size fits different head sizes
- Sweat absorbent and super comfortable
- Adjustable fit
- Machine washable
- Made in the USA
Cons
- As it is a doo rag, it won’t offer ear and neck protection.
#10 LAPCO LAP CC-7 1/4 Welder’s Cap
Specs
- Materials: 100% cotton
- Size: 6 ¾, 6-5/8, 6-7/8, 7-1/2, 7-1/4, 7-1/8, 7-3/4, 7-3/8, 4-5/8
- Gender: Men’s
- Color: Camo
This 6-Panel Welder’s Cap is a top-notch product for a good price. It comes in 9 different sizes ranging from 6 -3/4 inches to 7 – 5/8 inches, thereby offering you more options if you want the best fit.
Why Choose LAPCO Welder’s Cap?
100% cotton fabric construction
It allows you to use it for a long time without discomfort while working in hot work conditions.
Fitted design
The fitted design of this cap fits perfectly against your head. You can move around or bend down it without losing your hat.
Six-panel construction
It ensures a more customized fit. The panels are stitched together with Nomex thread. It holds together better than hats sewn with ordinary cotton thread.
Unique print
The cool and unique camo pattern incorporated natural shades and green and brown leaves, making it also perfect to use as a hunter cap.
Non-FR
As the fabric has no flame retardant coating, you can wash it by hand or washing machine.
Pros
- Great quality
- Well-made and durable
- Comfortable
Cons
- Not flame resistant
Best Welding Cap Buying Guide
Buying a weld cap goes far beyond just choosing a design. There are several factors to consider before picking one.
Let’s talk about these factors.
Fabric Type and Quality
The type of fabric used as the main materials determine your comfort level. When choosing a weld cap, go for high thread count cotton cloth-made caps.
A cotton cap is comfortable to wear and keeps the head cool in hot working conditions. Moreover, they are breathable and soft so you can pair them with your welding hood or helmet for extra safety from welding and other harmful stuff.
Check the cap features flat stitches and padded elastic at the seams to ensure your comfort.
Another important feature is checking for the fabric’s flame-retardant properties. FR welding cap prevents sparks and spatters from getting through the fabric and safe your scalp and hair from burning.
If you are a full-time welder, pick a lightweight, comfortable, breathable, and spark retardant cap.
Design and Coverage
Weld caps differ in design. Some have low crowns, while others have a high crown. Some come with a bill, while doo rags and beanies don’t include a bill.
The advantage of welding cap with bill is that you can turn it in multiple directions to get the coverage where you need. Shielding your neck and head is essential when you do overhead welding. By moving around the cap, you can protect your neck from flying sparks.
Again, when welding on a one-sided angle, it’s necessary to shield your ear and chin facing the welding arc. In these scenarios, you can turn the bill to protect your ear, neck, chin etc.
Check if it doesn’t have a bill, still offers sufficient coverage.
If your cap covers from the forehead to the backside and neck, it’ll be an added protection for you.
Also, check how many panels the cap has. In general, more panels mean the better the cap will conform to the head shape.
Cap Size
Manufacturers offer weld caps in different sizes. However, some caps are one-size-fits-most to fit most head shapes. In general, these caps include an elastic headband for a snug fit. But while choosing this size, ensure the elastic is not too tight on your forehead. I recommend going for a cap with a padded elastic headband.
Your weld cap should not be too loose or tight on your head. Check it comfortably fits your head, and you can move it around when needed. If the manufacturers include a welding cap size chart on their websites, you can check it for finding the right size cap for you.
Keep in mind that a cotton cap may shrink after the first wash. So, you need to consider the sizing before choosing one to purchase.
So, which are the best welding caps to get?
I hope this comprehensive list was helpful to pick the right one for you.
All the caps we’ve reviewed above are practical and functional that will protect your head while welding and let you focus on the task you’re doing.
These 10 choices are not only great for welders, but non-welders such as sprinklers, boilermakers, ironworkers, or pipefitters can also comfortably use them.
Pick any of the best welder’s caps from our list and keep your head cool and safe!
FAQs about Welding Caps
1. What is a welding cap?
A welder requires different safety wear or PPE (personal protection equipment) during welding work. A welding cap is a headwear on the head to protect the welder’s scalp and hair from flying welding sparks. Home improvement workers, including pipefitters and ironworkers, can use this headgear for safety and fashion.
2. What fabric is best for welding caps?
The short answer is cotton and other fire-resistive fabrics like Nomex are the best and safest options for weld cap materials. Cap made of synthetic fabric such as polyester or nylon is not a good choice to wear near welding or plasma cutting Since these types of fabric will ignite and burn quickly.
3. How long do welding caps last?
It depends on the fabric quality, frequency of use (and, of course, abuses).
4. Do welding caps cause hair loss?
Cotton or a soft type of weld caps won’t create this issue. However, if it is a hard hat/ cap that may put pressure on certain spots of your head, it may cause hair loss and permanent baldness over time.
5. Can I use regular caps for welding?
The answer is negative. Welding caps are specially designed and produced to offer head protection during the welding process. A regular cap or hat won’t have those particular features such as fire retardant, comfortable, durable, snug fit etc.
6. Why do welders wear their caps sideways?
There are different ways to wear a weld cap. When you turn the bill sideways and over the ear, it helps to keep the sparks out of your ear canal. It is essential when you’re welding on the one-side angle.
I’m Ivan D. Mitchell. I’m the Chief Engineer, Manufacturing Engineering Tool and Launch, specialising in automotive equipment design and build which meets World Class Manufacturing methodology. I have 15 years of work experience as a Tooling Specialist on some of the leading automotive manufacturing companies. When I launched this site, I wanted to create a platform where you’ll get everything about tools in one place. I also wanted to share my experience in the tool industry. I’ll do my best to share the information you need to truly make your tool using experience better. I hope you find our guides, reviews, information HELPFUL. If you have any inquiries, I’m always here to help you.
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