Best Welding Caps for Safety & Comfort [2020]

Top 3 Picks

pressed for time? Check out our top picks

best overall rating★★★★★

Tough Headwear Cap

Skull Cap Helmet Liner & Running Beanie Hat - Winter Cycling Hats & Ski Head Caps for Men & Women for Skiing & Workout - Ultimate Thermal Retention & Performance Moisture Wicking - Fits Under Helmets
  • Lightweight
  • Fabric is stretchy
  • Highly recommended
best overall rating★★★★★

Ergodyne Chill 6630

Ergodyne Chill Its 6630 Skull Cap, Lined with Terry Cloth Sweatband, Sweat Wicking, Blue
  • Highly absorbent
  • Highly durable
  • Rated well for comfort
best overall rating★★★★★

Revco REVCO – BC5W-BK

Revco REVCO - BC5W-BK Armor Cotton Welding Cap, 100% Cotton Double Layer Protection
  • Reasonably priced
  • Reputed brand
  • Fits perfectly

Welding is a very dangerous activity if not handled properly. There are extremely high temperatures involved and there might also be sparks and spatter that one needs to get adequate protection against.

Proper gear has to be worn which should be flame resistant yet comfortable enough to allow the wearer long hours of welding with ease.

One of the key parts of this protective gear assembly is the welding caps. These are important as they not only protect the head but can also make the wearer extremely comfortable while operating a welding machine.

They are indispensable and any professional would vouch for a good quality welding cap as a necessity.

Top Welding Caps Compared

ProductsSpecificationsPrice

Tough Headwear Skull Cap

Skull Cap Helmet Liner & Running Beanie Hat - Winter Cycling Hats & Ski Head Caps for Men & Women for Skiing & Workout - Ultimate Thermal Retention & Performance Moisture Wicking - Fits Under Helmets

Material: 11% spandex and 89% polyester
Colors: 8

Ergodyne Chill-Its 6630

Ergodyne Chill Its 6630 Skull Cap, Lined with Terry Cloth Sweatband, Sweat Wicking, Blue

Material: NA
Colors: 8

Revco REVCO - BC5W-BK Welding Cap

Revco REVCO - BC5W-BK Armor Cotton Welding Cap, 100% Cotton Double Layer Protection

Material: 100% double cotton
Colors: 1

Lincoln Electric Welding Cap

Lincoln Electric Welding Cap| Mesh Inside Liner | All American Print |K3203-ALL

Material: 100% Cotton
Colors: 2

Black Stallion BSX BC5B-BLU

Black Stallion BSX BC5B-BLU Black/Blue Cotton Beanie

Material: 100% Cotton
Colors: 1

Lincoln Electric Welding Beanie

Lincoln Electric KH823L Black Large Flame-Resistant Welding Beanie

Material: 100% Cotton
Colors: 1

Miller Genuine Welding Cap -230544

Miller Genuine Arc Armor Ghost Skulls Welding Cap 7-3/8' - 230544

Material: 100% Cotton
Colors: 1

Welder Nation Welding Cap

Welder Nation 8 Panel Welding Cap, Durable, Soft 10 oz Cotton Duck Canvas, for Safety and Protection While Welding (7 3/8, Ranch Tan/Olive)

Material: 100% Cotton
Colors: 5

Lapco FR Lap 6CFRGY7 Welder's Caps

Lapco FR Lap 6CFRGY7 1/4 Flame Resistant 6-Panel Welder's Caps, 100% Cotton, HRC 2, NFPA 70E, 7 1/4', Gray

Material: 100% Cotton
Colors: 6

Comeaux Caps Welding Cap

Comeaux Caps Reversible Welding Cap Solid grey Size 7 3/4

Material: 100% Cotton
Colors: 1

Reviews of the Best Welding Caps

best overall rating

Tough Headwear Skull Cap

Skull Cap Helmet Liner & Running Beanie Hat - Winter Cycling Hats & Ski Head Caps for Men & Women for Skiing & Workout - Ultimate Thermal Retention & Performance Moisture Wicking - Fits Under Helmets

This cap by Tough Headwear is designed like a beanie and can be comfortably worn under a welding helmet. It has high moisture wicking qualities that are useful in high-temperature welding situations.

Check out the features of this welding cap in a quick video.

Some of the key USPs of this welding cap are listed below.

Key USPs

  • Lightweight and comfortable
  • Fabric is stretchy
  • The brushed lining also supports thermal retention when needed
  • Made of 11% spandex and 89% polyester
  • Offers a 4-season performance
  • 4-way performance stretch
  • Lightweight at just 0.8 ounces

Pros

  • Very lightweight
  • Rated well for moisture wicking
  • Highly recommended by the users
  • Very comfortable to wear and compact
  • Works effectively as a helmet liner
  • Customers very happy with the customer service

Cons

best overall rating

Ergodyne Chill-Its 6630 Skull Cap

Ergodyne Chill Its 6630 Skull Cap, Lined with Terry Cloth Sweatband, Sweat Wicking, Blue

This skull cap by Ergodyne is available in a wide range of colors. It is made of a quick-drying fabric that is extremely useful when the temperatures can get soaring while welding.

This fabric allows for fast and effective moisture-wicking and quick drying, therefore, keeping the wearer comfortable.

Some of the key USPs of this welding cap are listed below.

Key USPs

  • Highly absorbent
  • Lightweight and very comfortable to wear
  • Highly durable
  • Reusable for a long time
  • Can be machine washed
  • Weighs just 0.8 ounces
  • Has a built-in terry cloth headband
  • Made of Hi Cool® moisture management performance fabric

Pros

  • Customers happy with the product
  • Rated well for comfort
  • Very absorptive and highly moisture wicking

Cons

  • Some customers found the cap to be too large
best overall rating

Revco REVCO – BC5W-BK Welding Cap

Revco REVCO - BC5W-BK Armor Cotton Welding Cap, 100% Cotton Double Layer Protection

Black Stallion manufactures a wide range of products that are welding gloves, hybrid welding garments, screens & frames, welding blankets, safety vests, leather equipment, backpacks, shields, etc.

They have over 43 years of experience in the industry. This Revco welding cap by Black Stallion is advertised as an armor welding cap. It has 100% double cotton layering.

Some of the key USPs of this welding cap are listed below.

Key USPs

  • One size fits all
  • Acts as a doo rag, welding cap, and a beanie, all in one
  • Weighs 2.24 ounces
  • Easily portable with dimensions 5 x 4 x 1 inch
  • Neck guard
  • Double-layer construction

Pros

  • Reasonably priced
  • Reputed brand
  • High level of comfort offered
  • Good quality welding cap
  • Fits perfectly
  • Well-made product
  • Stays in place

Cons

  • Some customers were unhappy that the product cannot be returned
best overall rating

Lincoln Electric Welding Cap

Lincoln Electric Welding Cap| Mesh Inside Liner | All American Print |K3203-ALL

Lincoln Electric needs no introduction when it comes to welding equipment and accessories. They offer a wide range of accessories to choose from and this offering is one of their welding caps.

This cap is made of cotton with a high thread count for the maximum possible comfort for the wearer. The design of the stars and stripes is an added plus.

Some of the key USPs of this welding cap are listed below.

Key USPs

  • Insiders are lined with a sweat-absorbent soft mesh that prevents hair pulling
  • Stitching of the seams is flat to avoid discomfort to the wearer
  • 100% cotton makes the cap breathable
  • Elastic is air-cushioned for adjustable fitting
  • Padded inside the elastic ring
  • Trusted and work by most welding professionals
  • Lightweight at just 1.12 ounces

Pros

  • Good brand repute
  • Lightweight
  • High rating for comfort
  • Great value for money
  • Great fitment

Cons

  • Manufacturing should be more consistent
best overall rating

Black Stallion BSX BC5B-BLU

Black Stallion BSX BC5B-BLU Black/Blue Cotton Beanie

Black Stallion offers a lot in the way of welding products and this particular offering is the BSX® welding beanie made of cotton.

Some of the key USPs of this welding cap are listed below.

Key USPs

  • Effective at keeping cool at high temperatures
  • Comfortable fir for most wearers
  • Flame resistant cotton construction

Pros

  • Extremely lightweight at just 0.32 ounces
  • OSFM sizing (One size fits most)
  • Stretchy fabric
  • Rated well for comfort
  • Great value for money
  • Perfect for hobby and professional welding applications
  • Well-made product

Cons

  • Product once ordered cannot be returned
best overall rating

Lincoln Electric Welding Beanie

Lincoln Electric KH823L Black Large Flame-Resistant Welding Beanie

From the wide range of products that Lincoln Electric offers, this is a beanie that is well-suited for welding operations. It protects the wearer against heat and spatters.

Some of the key USPs of this welding cap are listed below.

Key USPs

  • Made of cotton for breathability
  • The material used is lightweight (9 ounces) and flame resistant
  • Works as a good cushioning under the welding helmet
  • Size is highly adjustable and fits most
  • Part of the PPE series (Personal Protective Equipment)

Pros

  • Excellent value for money
  • High durability guaranteed
  • High level of comfort offered
  • Great product
  • Offers good protection against welding heat
  • Good brand repute
  • Good quality product with great construction

Cons

best overall rating

Miller Genuine Welding Cap -230544

Miller Genuine Arc Armor Ghost Skulls Welding Cap 7-3/8' - 230544

Miller Electric is known for offering a wide range of welding equipment for MIG, TIG, Stick welding, multi-process welding machines, etc.

Apart from these, they also manufacture protective gear like gloves, helmets, welding masks, caps, bandanas, safety glasses, apparel, etc.

This bandana by Miller is made of cotton and is a great lining for under the welding helmet while handling high temperatures. This product aims to wick the moisture and make it comfortable for the wearer to operate for longer hours.

Some of the key USPs of this welding cap are listed below.

Key USPs

  • 100% cotton construction
  • Includes a terry cloth insert
  • A sweatband is sewn into the cap for wearer comfort
  • Guaranteed with the Miller’s True Blue Warranty
  • Great fitment
  • Low crown
  • Reversible for greater flexibility
  • Lightweight at just 0.8 ounces

Pros

  • Good brand recognition and repute
  • Offers good protection
  • Good quality headgear

Cons

best overall rating

Welder Nation – 8 panel Welding Cap

Welder Nation 8 Panel Welding Cap, Durable, Soft 10 oz Cotton Duck Canvas, for Safety and Protection While Welding (7 3/8, Ranch Tan/Olive)

As the name suggests, Welder Nation offers a wide range of apparel and accessories to choose from dedicated especially to meeting the welding needs of the people.

One can choose from a host of jackets, hoodies, beanies and other headwear.

Some of the key USPs of this welding cap are listed below.

Key USPs

  • 8-panel welding cap
  • Soft and comfortable fabric (cotton canvas)
  • Lightweight at just 10 ounces
  • Long-lasting and suitable for heavy use
  • Made of duck canvas and insides are lined with moisture wicking fabric
  • Works under extreme conditions
  • Crown is 7 ½ inches deep

Pros

  • High-quality protection in welding operations
  • Available in a wide range of colors
  • Worth the price
  • Easily washable and does not fade or fray over time
  • No shrinkage reported
  • Good fitment
  • Offers great protection against sparks and spatter
  • Comfortable to use with hardhats

Cons

best overall rating

Lapco FR Lap 6CFRGY7 Welder’s Caps

Lapco FR Lap 6CFRGY7 1/4 Flame Resistant 6-Panel Welder's Caps, 100% Cotton, HRC 2, NFPA 70E, 7 1/4', Gray

These welding caps by Lapco have a 6-panel design and a low crown. They come in a wide range of designs that one can choose from and are a popular product with hobby welders as well as professionals.

Some of the key USPs of this welding cap are listed below.

Key USPs

  • The cap is reversible and pre-shrunk
  • Sizes available are 6 3/4 – 8
  • Available in different colors
  • Made of 100% cotton
  • Allows breathability even during long hours of usage
  • Backed by the Lapco warranty
  • Sewing is done with Nomex threading

Pros

  • Flame resistant
  • Lightweight at just around 3 ounces
  • Good fitting
  • Thick and durable material
  • Well-made welding cap
  • Comfortable to wear under welding helmets
  • Protects against heat and spatter

Cons

  • Some customers had an issue with the crown design
best overall rating

Comeaux Caps Welding Cap

Comeaux Caps Reversible Welding Cap Solid grey Size 7 3/4

Comeaux is a company that is dedicated to making welding caps and several other categories of caps. This particular product is a soft rimmed welding cap that boasts of a 6-panel design and a round crown.

It is available in one size fits most format in a wide range of colors.

Some of the key USPs of this welding cap are listed below.

Key USPs

  • Reversible cap
  • The measurement from crown to the bottom is 7 1/4 inches
  • All products go through a thorough inspection
  • Unique and varied designs
  • Medium crowned to protect neck and ears as well
  • 100% cotton fabric
  • Dimensions are 6.00 (in) x 9.50 (in) x 0.13 (in)

Pros

  • Reasonably priced
  • Available in a wide range of colors
  • Great aesthetics
  • Fitment is precise
  • Great level of comfort offered
  • Customers happy with the product
  • Rugged construction

Cons

The following sections of this article detail a buying guide for welding caps and this is followed by a review of the top ten welding caps and answering a few frequently asked questions about this product.

Buying Guide for Welding Cap

Some of the key considerations while purchasing a welding cap are listed below. This is by no means an exhaustive list but gives a fair idea about the important attributes that should not be missed out while purchasing a welding cap.

Material

Most welding cap materials should be sweat absorbent and lightweight. The preferable caps, in this case, would be those made of polyester on the outside with a cotton lining on the inside.

One could also go for 100% cotton welding caps.

Cotton is known for its ability to effectively absorb the moisture and keep the person wearing the welding cap cool.

One may also go for alternative fabrics that have a quick-dry technology to keep the wearer of the cap dry and comfortable.

Panel design

Most caps have a 6 or 8-panel design. The need for paneling arises from the need to tuck in hair and this design makes it easier to do so.

Keeping your hair out of your face while welding is not only more convenient but it also protects the wearer who might come in contact with sparks or flames from catching fire. This could be a crucial concern.

Moreover, the paneling also makes the crown of the cap fit better and therefore, makes for comfortable wear under welding helmets or other hardhats.

Flaps and additional fabric

Some welding caps don’t just cover the hair but also have flaps that run down the back and also additional fabric for covering the ears. These help in preventing the sparks from getting to the welder.

Cushioning

The insides of the cap should have an adequate lining of moisture-wicking fabric to prevent the wearer from getting uncomfortable due to sweating.

Apart from this, it should also have adequate cushioning to make the cap comfortable for someone who is going to use it for long hours.

Fitment

The sizing of the different welding caps available in the market varies from company to company. One should carefully check the proper size for themselves as these caps should not be too tight or loose.

To avoid this entire problem, there are caps fitted with elastics and made of a stretchy fabric that can be used by anyone.

Some One-Size-Fits-Most models can be used by most people without any concerns about the size.

Some of the other factors that can be considered while purchasing a welding cap can be the thickness of the material used as well as the threading. Both of these should be durable and flame resistant.

Apart from these, features like reversibility and ability to be machine washed make life much simpler for the wearer and would be a huge plus.

Several well-established companies in the market are known for producing premium quality welding accessories and one can find it easy to purchase these products.

However, there are other players as well that offer products of the same, if not better, quality at reasonable prices and there are a lot of sites where one can read the customer reviews of the same.

Purchasing a welding cap should solely rely on the comfort and discretion of the wearer.

FAQs

Why do welding caps have high crowns?

The high crowns are an integral and well-thought-out part of the design of the welding caps. When one finds themselves welding in odd positions where suppose, one is tilted to one side, they can easily pull the cap to that side and use the flap on the other end to cover their ears.

Exposure to the high temperatures of welding also means that there are a lot of sparks flying around and one would want to typically cover as much of their face, head, and back of their head as possible to prevent accidental burns. The high crown proves effective at preventing the sparks from running down to the back of the person. High crowns are typically useful in overhead welding and welding at odd positions.

What is the use of the flappy bills in the welding caps?

The flaps on a welding cap are typically needed for covering the neck and the ears of the wearer. These provide the protection needed for working at some odd angles.

What are welding caps made of?

Typically, a good quality welding cap is made of moisture-wicking fabric that is essential for operating at high temperatures. This makes cotton the top contender for making welding caps. Apart from this, if the cap needs to be stretchy to fit different people, most companies also make use of a polyester and spandex blend to achieve this. The lining inside, however, remains a cotton mesh or the like to get optimal results.

What are the important features that cannot be ignored when buying a welding cap?

Some of the most essential features for a welding cap are that it should be made of a flame-resistant material (including the threads used for sewing), should have additional layering for comfort and a higher degree of adjustment and it should also have flaps and additional cloth near the crown to prevent sweat from running off.

Summary

Having understood the need for safety when it comes to welding, it has become apparent that a welding cap can be a great add-on to the personal protective equipment that every welder has.

The choices to pick from are abundant, however, ultimately the decision depends on the person who has to wear and their purchase should rely solely on their comfort with the product.

There should be a priority given to function over style. The fitting, fabric, and design should all complement each other and together provide a feasible solution to the wearer against high temperatures and welding extremities.

Here are our top picks of welding caps again for you ->

 

Last update on 2020-10-21 / Affiliate links / Images from Amazon Product Advertising API

Harold Henderson
About Harold Henderson

Harold is a fitness freak and spends a lot of time in the gym. He also is a DIY-er and is proud of his collection of power tools. When free, he loves binge-watching Netflix series!

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