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7 Best Welding Caps in 2022 and Why You Need One

Do you do a lot of welding jobs, especially overhead welding? Do you deal with a lot of torch work? If you’ve said yes to one or both of these questions, then you definitely need a welding cap.

A welding cap is a critical piece of safety gear for anyone who welds. They feature a rear flap that can cover your neck fully while also protecting your head, ears, and hair from shards and sparks. Welding caps typically have a cotton lining with outer canvas/fire-retardant material on the outside.

In this guide, I’ll help you choose the best welding cap for your needs, and explain why you need one. Here are the topics:

  • What is a welding cap and why do you need one?
  • The 7 best welding caps on the market.
  • How to choose the best welding cap for your needs?
  • And more…
Picture of a welder wearing a welding cap under his hood.

What is a Welding Cap? Why Do You Need One?

Welding caps are critical for protecting your head, ears, and hair when welding. You can wear them alone or under your hard hat or welding helmet to make you more comfortable. They also help keep your head warm on cold days and prevent sweat from rolling down your face on hot ones.

You can click on this link to check out all the welding caps for sale on Amazon. But I encourage you to continue reading to learn about the benefits of welding caps and see my top choices with reviews.

#1. Enhance safety

Welding caps prevent hot sparks that fly around during the welding process from burning a welder’s skin and hair.

They are typically are made of protective, flame-resistant/fire-retardant materials and some even adhere to stringent ASTM standards. Many employers make welding caps mandatory on the job especially those in construction, automotive, forestry, etc.

Welding caps worn along with hardhats and helmets help enhance welders’ safety tremendously in hazardous conditions with chemicals, hot/molten metals, slippery surfaces, splashing liquids, and/or sharp falling objects.

#2. Prevent sweating

Welders have to work under hot and sweaty conditions. A welding cap made of cotton can absorb the sweat under a welding helmet. This can enhance a welder’s comfort. Some caps also feature a soft athletic mesh inner lining that keeps the head cool and airy. Moreover, caps strengthen the grip and ensure a better fit of the hardhat or helmet.

#3. Simply as a fashion statement!

The use of modern and stylish welding caps is not limited to welding alone. You can also use these caps under your motorcycle or bike helmet or standalone for fashion and style. These days, you get funky colors and patterns in men’s welding caps – from half-naked ladies to stars and stripes to skulls and bones – take your pick!

7 Best Welding Caps – 2022 Top Picks

#1. Winner: Welder Nation 8-Panel Welding Cap

If you are into welding, cutting, grinding, and other rough jobs, then the Welder Nation welding cap is a must-have. It will give you an extra layer of safety without sacrificing comfort.

Several features make the Welder Nation 8-panel cap a winner in our books:

  • It is made of canvas and cotton. The cotton absorbs the sweat under a hard hat or helmet while the canvas withstands heavy usage and keeps the cap long-lasting.
  • Welder Nation is a reputed brand that tests its products. They have subjected their welding caps to extreme working conditions and they have withstood them very well.

Physical features

  • Innovative 8-panel design of duck canvas outside and soft 10 oz. cotton layer inside
  • Available in 8 sizes and 8 attractive colors.


  • Lightweight and comfortable
  • Breathable
  • Versatile: can be worn frontways or backways
  • Color remains bright and vibrant months after use.


  • Shrinks a bit after washing. Buy a size larger than usual.

Expert tips

Do not put the cap in the dryer after washing. Let it air dry.

How it compares

Welder Nation welding caps may be slightly expensive compared to some of the entries below. However, they are extremely well-made and feature an innovative design. They are lightweight, breathable, and comfortable., so much so that you won’t realize you’re wearing one! These versatile and attractive caps can even enhance your style quotient on the weekends!

#2. Best Overall: Lincoln Electric Store Welding Cap

Lincoln Electric Store’s welding caps cost around $10 less than our winning entry above. However, its low price has not prevented it from having several superior features. This makes make it one of the best welding caps in our books!

Physical features

  • Made using 100% breathable cotton
  • Inner padding and air cushioning for utmost comfort
  • Elastic band to fit multiple sizes
  • Mesh lining for absorbing sweat


  • Choice of professional welders
  • Comfortable, soft, and airy
  • Absorbs sweat
  • Stylish and functional
  • Value for money; very affordable


Runs small. Gave some welders a headache after constant use.

Expert tips

You can loosen the elastic or remove the stitches to make it wider.

How it compares

Lincoln Electric is a solid company with a good reputation. Their welding cap is affordable and you can buy multiple caps for variety. The material absorbs sweat and keeps the user’s head cool and comfortable under the helmet. You can even wear it for motorcycle riding under the bike helmet.

#3. Best Budget: Riverweld Store Fashionable Welding Cap Under $10

Riverweld welding caps are priced under $10. They are made of pure cotton. You also get them in several patterns and colors, so you literally have one cap for each day of the week!

Physical features

  • Single size fits various head circumferences
  • The perimeter of the cap is 23.6 inches/58 cm depth of 20 cm. Easily fits average-sized heads of 23-inches. The sides are elastic and stretch.
  • 100% cotton
  • Available in various colors.


  • Can be worn with any helmet
  • Lightweight and comfortable
  • Machine-washable
  • Stylish
  • Affordable
  • Sweat absorbing


  • Runs small.

Expert tips

  • Loosen the elastic a bit to make it fit if your head size is over 23 inches.

How it compares

For under $10 Riverweld welding cap is one of the best in the market. However, users have reported a few size issues, so make sure you measure your head circumference before ordering. It may not be suitable for people with larger head sizes. Other than that, the material is comfortable and absorbs sweat. Riverweld cap is also stylish and available in various colors and prints.

#4. Best Safety Rating– Fullsheild FR Men and Women Welding Cap

Fullsheild FR reversible welding cap has many superior features that make it one of the safest welding caps. These reversible caps are also flame retardant on both sides and meet ASTM F1959/F1506 standards.

It is also available in two size options of a low and high crown; a feature beneficial for welders with irregular head sizes. It can easily fit head-circumferences between 22-24 inches.

Physical features

  • Tear-resistant lining; durable flame retardant cotton with double layer.
  • Reversible
  • Versatile- can be used not only for welding but other jobs like automotive, electrical, etc.
  • Elastic and stretchable
  • Dimensions are: the front flap of 3.3-inches, circumference – can fit head sizes of 22 to 24.5 inches, depth of 7.1-inches.
  • Meets ASTM standards
  • Flame retardant cap finds use in 
  • Available in 8 attractive colors and 2 sizes: low crown and high crown.


  • Durable and tear-resistant
  • Available in 2 size choices, unlike other welding caps that usually come in one size only.
  • Flame retardant
  • Registered brand
  • High-quality assurance
  • Versatile – useful in various applications. Fashionable enough for daily use or as a sports cap.
  • Meets industry standards


  • Slightly expensive compared to other caps.

Expert tips

  • Use standalone or as a lining under helmets or hardhats. The flap can protect the neck while welding.
  • Hand wash and air dry to prevent shrinking.

How it compares

Fullsheild FR reversible caps are versatile. They meet ASTM standards which many welding caps in the market don’t. They have a double fire-retardant layer which makes it suitable for various industries. You also get a choice of colors and 2 crown sizes. Price-wise too, it is half that of our winning entry.

#5. Best Reversible: Comeaux Caps Reversible Welding Cap

Comeaux’s welding cap is reversible and comes in stylish black color on both sides. They have a medium-to-deep crown depth that fully covers the head, ears, and neck.

Physical features

  • 100% cotton with 6 panels
  • Size 7 1/8th inch


  • Value for money
  • Reversible
  • Fit well
  • Stylish
  • Lightweight
  • Durable
  • Undergo strict inspection 


A few users reported some size issues.

How it compares

Comeaux’s reversible welding cap is functional and stylish. It comes at an affordable price and is lightweight and comfortable.

#6. Best Extra-Large Welding Cap: Just In Trend Flame-Resistant Welding Cap

Some welders experience a headache if they wear caps that are too restrictive. Even the regular-sized 22-inch caps tend to shrink and constrict while in use. This leads to discomfort for most users. Just-In-Trend company has overcome this drawback by developing these extra-large welding caps.

Just In Trend welding caps are available in Large (7 ¼) and Extra-Large/XL (7 ½  )US sizes. In inches, these can fit head circumferences between 22.8 to 23.5-inch.

Moreover, their welding cap also conforms to the highest standards of safety.

Physical features

  • Made with 100% cotton – Fabric is compliant with various NEPA and ASTM standards for arc flame and flash flame fire.
  • Lightweight – weighs just 7 ounces
  • Reversible
  • Double layer
  • 6 panels
  • Available in Regular, Large, and Extra-large sizes
  • Shrink-resistant


  • Safety, performance, and style
  • Made with the highest safety standards
  • Unique design
  • Lightweight, comfortable, and breathable


Some users found the fit odd as the crown is slightly higher than usual caps. It leaves a gap above the head which may feel odd to some users.

How it compares

The bright orange/rust red color of the Just In Trend flame-resistant welding cap is sure to help you get spotted easily. This is one of the few welding caps that come in large and extra-large sizes. So welders with larger heads will benefit from their use. However, the dome of the cap is tall so it could present an issue to some users. Their price is modest and reasonable.

#7. Best Welding Beanie Cap – Lincoln Electric Beanie

Welding beanies cushion your head against the hard hat or helmet. This offering from Lincoln Electric is made of flame-resistant material and can protect your head from heat and sparks.

Physical features

  • 9-ounce, single layer
  • Made of flame-resistant cotton
  • Available in Large and extra-large sizes to fit head sizes from 7 to 7- ⅜. Has a small bungee/elastic band on the back for some more size allowance.


  • Comfortable
  • Safe and functional
  • Lightweight
  • Value for money


  • For some users, the beanie did not stay put.
  • Unlike regular welding caps, it does not have a neck flap and may not protect your neck from sparks.

How it compares

For less than $5 this welding beanie is truly affordable. It fits well for most users. The flame-resistant beanie is sure to find application in many industries.

Picture of a man wearing welding goggles

How to Choose a Welding Cap for Your Needs?

Here are some factors to consider when selecting a welding cap:

#1. Safety standards

Choose a welding cap that meets the safety requirements of your job. Some jobs require flame-resistant caps; others could do without the flame retardant property. Some jobs need the welders’ work attire to meet strict ASTM standards. Select a welding cap accordingly.

#2. Size

Measure your head circumference just above the brows by taking the tape around. In inches, it will be a number between 22 and 24. The average male head circumference is 22 ½ inches.

Most men can use a cap between 7 to 7.5 US sizes. If needed, buy several welding caps and try them on. It could be that the usual size ends up being too restrictive for you after wearing it for while. This could result in headaches. Bear in mind also that caps tend to shrink after washing – therefore, buying a size larger than usual could be practical.

Many welding caps come with an elastic band that allows stretching. This helps accommodate larger head sizes.

Some welding caps come in one-size-fits-all. These may not be suitable for you if you have a larger-than-average-size head.


Often, welding caps have a reversible feature. This is useful if you want to display different colors of the cap. Reversing the cap is also helpful when your head gets too sweaty under the helmet.

Some caps are beanie-style. These may not offer much in the way of protecting the neck. Choose flap-based welding caps if your work entails overhead welding or requires protection from the sparks for the neck area.


Why Are Welding Caps Worn Sideways?

Welders often wear welding caps sideways to protect their ears. The cap covers the ear from getting burnt by stray welding sparks.

How are welding caps supposed to fit?

Welding caps should have a snug fit. They should not be too tight as that could lead to headaches. They should not be too loose else they might come over your eyes or make it very uncomfortable to wear a hard hat or helmet over it.

How to stretch a tight welding cap?

If your welding cap is too tight, we suggest buying a size larger than the one you have. You could try stretching the elastic band of your existing welding cap but there is a risk that you could snap it and render it useless.

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