Best Welding Caps of 2022 – Reviews And Buying Guide

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Welding caps are worn as protection for the head while you are welding. These caps are often worn backward while the welder is wearing their welding hood because while the cap is turned backward if small BBs of hot metal strike the top of the welders head it will hit the brim of the cap and roll to the floor instead of down the collar of the worker’s shirt.

These cloth caps are essential equipment for people doing this work.

best welding cap

You have to have the best welding caps as they help to control longer hair and keep that hair from getting in the way of their vision, or worse keep that hair from being sung while they are welding.

We asked a lot of welders what makes one cap better than another and they gave us a list of great features. We have included caps that have all of those features in our top picks for 2022.

Comparison Chart Of Our Best Picks





Welder Nation 8 Panel

Innovative 8 Panel Pattern. Exterior of cap

Lincoln Electric K3203 Welding Cap

Made from soft, high thread count cotton

BSX Gear BC5B-BK Welding Beanie

Size fits most elastic stretches to fit most heads

Comeaux Caps Reversible Welding Cap

6 Panel Cap Reversible

Lapco Lap Panel Welder Cap

Size 7 1/4 Camo Hat.

Lapco FR Lap 6-Panel Welder's Caps

Sewn with Nomex thread

Best Welding Cap Reviews - 2022

1. REVCO - BC5W-BK Armor Cotton Welding Cap 


  • Weight: 2.24 Ounces
  • Dimensions: 5 x 4 x 1 inches
  • 100% cotton
  • Double layer protection
  • One size fits all
REVCO - BC5W-BK Armor Cotton Welding Cap

Among various welding caps on the market, the REVCO – BC5W-BK Armor Cotton Welding Cap is a peak item to buy. With its excellent built and protective layer, you can weld your metals with complete safety. The welding cap comes in black and has an affordable rate.

The experienced brand Revco designed this cap thinking about all types of consumers. So, it fits on most head sizes. You can simply adjust the cap on your head with no issue. This item is comfortable to wear and will not make you feel uneasy.

Built with cotton, you can completely trust the durability of its materials. The hood in the front will make sure to protects your forehead and eyes from dangerous particles in the air. It is very lightweight, and while wearing this, you might not even feel any weight on your head.

For making it fireproof, the manufacturers used only the highest quality cotton on it. Because of that, not only is it tear resistance, but it will also prevent your head from being sweaty. As welding is dealing with flames, you can safeguard your hairs from flaming particles or fumes. It will be a wise purchase for sure.


  • 100% Cotton with double layer protection
  • One Size fits for all
  • All in one cap for welding - Cap, beanie and Doo Rag
  • Durable and safe for professional welding
  • Breathable, flame resistant and keep you safe and comfortable at a higher temperature.


  • Fits best on smaller coneheads, not perfect for a bigger one

2. Welder Nation 8 Panel Welding Cap


  • Weight: 2.4 ounces
  • Dimensions: 11.25 x 7 x 0.5 inches
  • Innovative 8 Panel Pattern
  • Made with duck canvas
  • Stands up to extreme work.
Welder Nation 8 Panel

We have another cool-looking cap on our list that comes from a renowned brand, the welder nation. The Welder Nation 8 Panel Welding Cap is guaranteed to keep anything harmful from your head and eyes. People throughout the USA are using this cap on various welding projects.

Since arcs and sparks can be dangerous for your hair, this machine is especially arc-proof. You can go for your MIG, Tig, stick arc welding without any worry. With the black on white look, it will also make you stand out.

It only weighs 10 ounces, no burden on your head. But do not question its durability as the cap is of the carefully selected cotton duck canvases. Welders praise its longevity in harsh environments.

It has unique eight-color panel patterns that you can choose from. While the outside is of duck canvas, the inside contains cotton lining. It can withstand flames, sparks, and cold weather.

We have seen people using this welding cap along with coveralls and jackets. You can buy the product in 10 different sizes. This item has high ratings based on its comfort and durability.


  • 10 Available Sizes
  • Different color options are available
  • Durable but soft cotton canvas material used for long-lasting and heavy-duty work
  • New and Innovative 8-panel design


  • Slightly deep and sometimes not comfortable for some people

3. Lincoln Electric KH823 Black Large Flame-Resistant Welding Beanie


  • Weight: 0.010 ounces
  • Dimensions: 11 x 6 x 1 inches
  • Model Number: KH823L
  • Size: Large
  • Color: Black
Lincoln Electric KH823 Black Large Flame-Resistant Welding Beanie

If you research welding products, you should have heard about the Lincoln Electric brand. Their Lincoln Electric KH823 Black Large Flame-Resistant Welding Beanie is an excellent item to own. Like all other Lincoln products, this item was crafted with all the necessary factors in mind.

You can purchase this welding beanie at a cost less than your lunch money. As the product is made from cotton, you can prevent getting any spatter or flame particles on your hair. The cotton also makes it more comfortable and easier to adjust.

You may even forget that you are wearing anything as it weighs 9 ounces only. Another great feature is, it has the perfect shape to wear a welding helmet on it. So, you can have double the protection. You can find it in sizes from 7 to 7-3/8. The welding beanie also looks excellent and pretty.

We should not gloss over the fact that this item is machine washable. Hence, you can use it for a long time without any tearing or wearing. And it will save you money from buying new welding caps as well. Experts recommend this welding beanie to all welding enthusiasts.


  • Great breathability
  • Easily fit under a helmet
  • Flame Resistant
  • Made of high-quality cotton


  • Larger sizes are available only

4. Lincoln Electric K2994 Welding Beanie


  • Weight: 0.8 ounces
  • Dimensions: 6 x 1 x 1 inches
  • Size: 7.0 -7.25
  • Installation Method: Arc-welding
  • Item number: K2994-ALL
Lincoln Electric K2994 Welding Beanie

When it comes to quality, the Lincoln Electric K2994 Welding Beanie is incomparable. It comes in the perfect shape and design to cover up your entire head and forehead. As we tried the item in various environments, it never showed any sign of failing or flaws.

Available in sizes from 7 to 7.5, you are free to go for the size that fits your head. Since it is totally flame resistant, you will not have any harmful sparks on your top. But the creators definitely remembered to keep it comfortable for the user. So, the item is only 9 oz.

It will keep your head cool from all the dangerous rays from the sun. This welding beanie includes excellent cotton fabric in its body. It won’t get any damage from water and is anti-mold. Speaking of materials, the fabric is lined in a way to keep the air circulation smooth.

It is totally tear-resistant. For achieving that, Lincoln used several layers of stitches so that the seams stay okay in all conditions. Lincoln is proud that this welding beanie is a top-demanded product in their shops. We think that you should get it too.


  • Anti-static and anti-mildew coating
  • FR Fabrics to protect your head from flames and fires
  • Not suffocating at all, besides the breathability, it is designed for maximum comfort
  • Durable and long-lasting
  • The seams have a multilayer pattern for preventing the tears and rips


  • Not one-size-fits-all

5. Lincoln Electric K3203 Welding Cap 


  • Weight: 1.12 ounces
  • Dimensions: 6 x 1 x 1 inches
  • Part number: K3203-ALL
  • Material: Cotton
  • Measurement System: US
Lincoln Electric K3203 Welding Cap

This cap is made from high-quality cotton that is soft and feels good against your head. The high thread count in the cotton also adds to the fire resistance of the material making this a safe hat to wear.

The stylish red, white and blue design with the stars and stripes makes the cap fashionable and unique. On the inside of the hat, there is a soft athletic mesh sewn in.

This mesh helps to wick moisture away and help reduce sweating, and the incidence of sweat running down your head and trickling into the nape of your neck. This mesh also reduces the incidences of your hair being pulled by the cap while you wear it.

The seams are flat stitched so they are more comfortable and do not create the same irritation and soreness than normal seams are capable of. The flat seams also increase the durability of the cap. It lasts longer and stays looking good for longer.

This cap has a brim that you can turn to protect your ears or the back of your neck while you are welding. It gives you comfort and peace of mind knowing that you are protected from possible injury.


  • Soft quality cotton
  • Soft athletic liner for absorbing moisture and preventing hair pulling
  • Great Breathability and Durable.


  • Though the manufacturer claimed it as fit for all for its elastic headband in reality this is not perfect for a bigger head

6. BSX Gear BC5B-BK Welding Beanie


  • Weight: 0.64 ounces
  • Dimensions: 9 x 6 x 1 inches
  • Part number: BC5B-BK
  • Material: Cotton
  • Manufacturer: Black Stallion
BSX Gear BC5B-BK Welding Beanie

This is a 100% cotton hat. The cotton material is the safest material for someone who is welding to wear on their head. Cotton naturally resists flaming so it protects your head without erupting in flames from exposure to a spark or hot piece of metal.

This cap is specifically designed to protect the top of your head and your hair. If a spark lands on the top of your head it is not likely to catch your hair on fire or to burn you. The cap will be insulating you against this painful occurrence.

The cap does not have a brim that you can turn to the side to protect your ear or turn to the back to protect your neck. It is designed bill-less. It fits snugly on your head and protects the crown of your head from possible injury from a spark or hot metal.

The cap can create a cushion between your head and the welding hood that you wear. Sometimes welding hoods can rub and irritate your head but this cap prevents that from happening.


  • Sturdy FR cotton
  • One size fits
  • Comfortable and Weighs only 0.64 ounces


  • Shrinks after washing

7. Comeaux Caps Reversible Welding Cap


  • Weight: 2.18 ounces
  • Dimensions: 8.5 x 6.1 x 1.89 inches
  • Part number: 20700 Blue Bandana
  • Material: Cotton
  • Size: 7
Comeaux Caps Reversible Welding Cap

This welding cap is made from a material that resembles the most common bandana fabric. It is a 6-panel reversible hat that is made from 100% cotton. !00% cotton is the safest fabric to wear in welding situations.

The cotton is naturally fire-resistant and will actually extinguish small fires. It is also capable of allowing hot sparks to strike it and the hot metal pieces to roll off of the fabric without doing any damage to the fabric,

This cap fits snugly on your head and does not shift and move around. You can do your work, bend over, and move any way that you need to and the cap will stay in position. This is a safety feature because when a cap moves while you are working it can be distracting and cause you to make an error in judgment or cause you to be injured.

This cap can be reversed, and it can be worn turned so that the bill protects your ear canal. It can also be worn backward so the bill protects the back of your neck.


  • 100% Pure Cotton
  • Extremely lightweight and comfortable having only 2.18 ounces
  • Cap remains intact and not displayed while removing the goggles and helmets


  • Only 1 size available

8. Lapco Lap Panel Welder Cap


  • Weight: 2.72 ounces
  • Dimensions: 12.2 x 7.8 x 0.3 inches
  • Part number: LAP CC-7 1/4
  • Material: 100% Cotton
  • Size: 7 1/4 Camo Hat
Lapco Lap Panel Welder Cap

This cotton welding cap is Not Flame resistant. It is made from 100% cotton and 100% cotton does have flame-resistant properties naturally. If a spark hits the hat it is not likely to ignite because the cotton is designed to extinguish small flames.

It is a fitted cap so it will fit tightly against your head and is not likely to be easily knocked off. You can bend down and move around without losing your hat.

The stitches of the hat are made with Kevlar thread. Kevlar thread is flame resistant and can withstand great temperatures and exposure to high heat situations without becoming compromised. Hats sewn with Kevlar hold together better than hats sewn with ordinary cotton thread. This one is one of the best welding caps on the market.

This hat has a unique camo pattern that incorporates leaves and natural shades of brown and green. It weighs 2.72 ounces and is very easy to clean and maintain. You can wash the cap by hand or wash it in a washing machine. It is not coated with a flame retardant so you will not change the dynamics of the hat by laundering it frequently.


  • Pure Cotton
  • Non-FR Technology
  • Sewn with Exclusive Nomex thread
  • 9 different sizes are available


  • They used so many extra materials on the top, you can’t wear a hardhat on it

9. Lapco FR Lap 6-Panel Welder's Caps 


  • Weight: 3.2 ounces
  • Flame Resistant.
  • Part number: LAP 6CFRGY7 1/4
  • Material: 100% Cotton
  • Size: 7 1/4 6-Panel FR Gray Hat.
Lapco FR Lap 6-Panel Welder's Caps

This is a fitted cap that fits snugly on your head covering your hair from possible sparks. It is made from 100% cotton material that is flame resistant. It is sewn together using Kevlar thread.

The Kevlar stitches can withstand the high heat and exposure to sparks where other threads could not. Kevlar thread does not ravel or fray so it is less likely to succumb to a spark and is more likely to make your hat last longer.

The cotton is treated with a flame retardant that makes it flame resistant. The flame resistance can sometimes be diminished by frequent washing of the cap. 100% cotton that has a tight weave like the material on this cap will actually be very hard to catch on fire or to burn once it catches on fire. This type of cotton is naturally flame resistant and will extinguish a fire from a small burn.

It is made to be reversible so you can wear it turned inside out if you wish. The fabric is heavy and works well to turn sparks so they do not enter an ear or fall down your collar.


  • Made of 100% Cotton
  • Nomex thread makes it Fire and Flame Resistant Feature
  • 12 Different Sizes are available


  • Best for coneheads only

How To Choose Welding Caps: Buyer's Guide

Before you buy a welding cap consider the frequently found features and decide which cap has the features you desire.


You can buy a welding cap that has a brim or you can buy them in a beanie style. The caps that have no brim provide less protection for your ears and the back of your neck.

You can turn a brimmed cap to the side to stop sparks and pieces of metal from being able to fall into your ear. You can turn the brim backward to stop sparks and pieces of hot metal from being able to go down your collar.

The beanie does not have brim protection but they are comfortable and they fit better under your welding hood because they do not have a brim getting in the way. The beanie style does protect the crown of your head and your hair from exposure to sparks.


You want a welding cap that is made from 100$ cotton. 100% cotton is hard to ignite because of it naturally resists flame. It is a safe material that is better suited to protect your head while you weld,

Some cotton has a higher thread count. You will get a softer feeling hat from a cap made from cotton with a high thread count.

A cap that is stitched together using Kevlar thread is more likely to last longer without coming apart. Kevlar thread is designed to be tough and heat resistant.

Flame Resistant

Some caps are saturated with a flame-resistant substance to increase their ability to protect you from flames. This flame resistance is a bonus but is not absolutely necessary.

Reversible or Lined

Some caps are sewn so that they are reversible. Often these caps are one color on the outside and the inner lining is made from a different color.

Some caps are lined with mesh that is supposed to help reduce the amount of hair pulling your experience. The greatest thing about the mesh-lined hats is they help absorb moisture and keep you from being so hot and sweaty.

Frequently Asked Questions

Q. What are welding caps for?

Welding caps are safety devices created to help reduce the possibility that a spark would land on your head and ignite your hair. They are also designed so the bill of the cap can be used a protective shield for your ears when the cap is turned sideways and for the back of your neck when the cap is turned around backward.

Q. How do you make welding caps?

You will need a pattern and about ¼ yard of good heavy cotton fabric. You lay the fabric out and pin your pattern to it. Then you cut the pattern out using a rotary cutter or sharp scissors.

You will need some interfacing to iron onto your material to make the brim of the hat strong and able to hold its shape. Sew the top sections and the side pieces together. Then you sew the front section and the back section to the top and side pieces. Trim the threads.

Q. Do you need a welding cap?

Yes, you really do need to wear a welding cap to protect you from possible injury while you are welding. The welding cap covers your hair and protects you from singing your hair. It also can be positioned to cover your ear or the back of your neck from sparks and hot pieces of metal.

Q. Why do welders wear white caps?

White caps are often worn by welders because white caps are said to be cooler than darker colored caps. When you are welding it gets very hot under the welding hood so wearing a cap that will help keep your head cooler is a wise decision.

Final Note

Welding caps are essential wear. They protect your head and if you are looking for a high-quality welding cap that does not have a brim then you need to check the 

BSX Gear BC5B-BK, This hat is made from 100% cotton and it is comfortable and convenient to wear.

If you are looking for a brimmed hat that is stitched together with Kevlar thread then you should consider the Lapco Lap Panel Welder Cap. It is a high-quality cap made from 100% cotton and crafted to be durable.

Last Updated on 1 year by Richard Boyer

  • June 28, 2022
Richard Boyer

Richard Boyer has been a professional welder for over 27 years of his life, and now he is a trainer and blogger providing critical information to anyone interested in welding. He is helping out both hobbyists, novice and professional welders to learn newer and better techniques. Read more about me

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