Best Welding Caps

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If you are a welder, you might have considered a welding cap for protecting your hair. When working, it is not uncommon for splatters or slags to get into your hair. In addition, accidents have happened where welders have had the misfortune of going bald sooner than intended, which is why getting a welding cap is necessary. Always have proper head protection, even if you feel safe; a welding cap will help reduce any chance of an accident. 

If you need help knowing where to start, you are at the right place. We have prepared a list of the best welding caps to get. Whether you already have a welding cap and are looking to get another, or this is your first time getting a welding cap, you will benefit from our well-detailed reviews of the best welding caps. Read on. 

Comparison Chart

51lPp EKqGL. SL500
Lincoln Electric unisex adult Flat Lincoln Electric Welding Cap
41SDTD6wDhL. SL500
Welder Nation 8 Panel Welding Cap
41DwIw1DlvL. SL500
Revco REVCO – BC5W-BK Armor Cotton Welding Cap
315vGKzUytL. SL500
BOCOMAL Welding Cap HRC2 Flame Resistant
41WVYfHNcUL. SL500
Miller Genuine Arc Armor Ghost Skulls Welding Cap

Welding Cap Reviews

1. Lincoln Electric Unisex Welding Cap 

51lPp EKqGL. SL500

Lincoln Electrical designs started in 1895 in Cleveland, Ohio. They develop and manufacture arc welding solutions, plasma & oxy-fuel cutting systems, and robotic welding systems. Their solutions are popular and used in more than 160 countries in diverse industry sectors. 


The Lincoln welding cap is lightweight and breathable. It constitutes premium cotton fabric with a design that allows for a two-way airflow to keep you cool whenever you work. In addition, the stylish stripes and stars pattern adds a little flair to the fabric and makes you stand out when wearing it. Lincoln Electricals wanted this cap to help welders. The inside of the athletic mesh is a sweat-absorbent mesh liner, making it usable for many hours at a time. It not only absorbs sweat but also improves comfort, thus allowing you to have it on for long hours. 

Most caps usually create a sense of discomfort when the seams come into contact with the skin. This one, however, does not; it features flat-stitched seams everywhere. This not only prevents discomfort but also increases its durability. You can be sure it will not get caught in your hair as most hats would. 

Whether it will fit you or not, a padded elastic headband offers a snug, comfortable fit. However, you may need to stretch it out as it can be too tight if your head is larger than the average size. There have been complaints about inconsistencies when it comes to sizing. If your head is too small or too large, you might have a problem with the fitting.

Some people have opted to cut the elastic ring just so that it could fit. However, other than this, it is overall a tremendous cap. Professional fabricators use this cap daily, and it works for them just fine. It stops the welding sparks and is perfect for protecting the back of your neck.


  • It comes with a padded elastic ring
  • Absorbs all the sweat and offers comfort at the same time
  • Flat stitches make it durable and prevent discomfort
  • The material used to make it is breathable to cool you off
  • It is lightweight
  • Has a stylish stars and stripes pattern


  • Inconsistencies in sizing mean it might not fit you

2. Welder Nation Welding Cap 

41SDTD6wDhL. SL500

This unisex welder cap from Welder Nation is made from soft cotton canvas and offers protection and safety when welding. The material is of high quality and it is durable. Welder Nation is known for its broad collection of apparel, headgear, welding gear, and many other accessories. The company also gives back to the community through its generous contributions to children’s hospitals and the Veterans Welding Training Programs.


Regarding your safety and protection, we believe in getting the best quality possible, even if it is pricey. That is how we feel about this welding cap. The highlights of this cap are resistance and durability. This cap has undergone testing in the harshest of conditions and has stood the test of time. So, if you are a rugged individual or generally a rough user, this cap will suit you just fine as it doesn’t ruin easily.

It constitutes a 10 oz cotton canvas. This material is unique for a welding cap because the type of cotton used to make it is the same one used to make overalls and welding jackets. Knowing this, you don’t have to worry about longevity. Comfort is another strong point of this cap, courtesy of the eight panels. It features a duck canvas exterior and extensive panels to allow for breathability. Additionally, it allows for airflow to move both in and out. When it comes to sizing, there are 10 different sizes available. Thus, you will find a perfect fit for you. Check out the fitting chart and pick your appropriate size. 

The Welder Nation cap will still be comfortable even after working long hours. You won’t feel tired, and in addition to that, it won’t get caught in your hair. Washing is also pretty easy.


  • It is resilient and durable
  • Easy to clean
  • Comfortable courtesy of the eight-panel pattern
  • Soft cotton canvas will last a long time
  • It is breathable 


  • Relatively expensive

3. Revco BC5W-BK Welding Cap

41DwIw1DlvL. SL500

If you’re looking for a cap with an attractive style, this is the one. The design is unique compared to other caps, which is even more favorable for you because it is cheaper. It has several great qualities and features that make it stand out. The BC5W-BK is 100 percent cotton and offers double-layer protection.


If you are tight on cash and looking for a quality cap, get the Revco BC5W-BK. It is a comfortable fit for everyone. Even though it is affordable, it has outstanding qualities, the first one being it cools you off. Since it is made entirely of cotton, your head won’t heat up as you are working; it allows air to flow in and out. The breathability is great to have when you are working as you won’t feel any discomfort even when you leave it on for long hours.

As with most caps, the Revco BC5W-BK has an elastic band to ensure it fits perfectly. The cap’s brim extends down to your neck, allowing you to cover your hair and keep it tucked in to prevent accidents. You can be sure that this cap will last you a long time, courtesy of the double-layer cotton. However, when you regularly wash it, its lifespan will reduce tremendously. It is also worth mentioning that it can absorb sweat, so you don’t have to be concerned about taking it on and off to wipe off sweat when working. 

However, a downside with this cap is that the stitching is not necessarily done correctly, thus giving you a scratchy sensation. Users of this cap have also complained about the elastic being very tight, so if your head is bigger than average, you should skip this one. The last thing you would want when working is to have to remove your cap for relief every few hours.    


  • Absorbs sweat
  • Made out of thick material
  • Relatively cheaper than other brands
  • Usable on several occasions
  • Comfortable and offers protection


  • Tight fit on big heads

4. Bocomal Welding Cap

315vGKzUytL. SL500

Innovative caps are standard these days, but finding ones that are exceptionally unique and stand out in their way is rare. Bocomal, the maker of this cap, has been in business for over a decade. They have a dedicated team of safety specialists and designers that make high-quality flame-resistant clothing. Even though they have done pretty well in recent years, they still strive to challenge themselves. Their goals involve making clothing that is both comfortable and durable and offers you protection.   


The material used to make this cap is solid and sturdy. With respect to the stitching, it feels good when it comes in contact with the skin, unlike others that cause an itching sensation. You could wear this cap for long hours without any irritation. Wearing it gives a sense of naturality when you compare it with other welding caps. When purchasing, you have options to choose from; they are available in the colors brown, green, and black. You can also select multiple packs when checking out.

The cap also has new features on the surface: it is oil-resistant and water-repellent. The manufacturers utilized a 10 oz heavy-weight flame-resistant duck cotton on the outside for protection. They didn’t leave out the inside either; it has 6.5 oz flame-resistant cotton. It is also two-sided; both sides have been stitched well with strong threads allowing you to turn it into either side and still style it confidently. The six-panel design adds a cherry on top as they come in different colors and make the caps look even more beautiful. 

This cap is easily washable. The manufacturers recommend machine washing it. When you wash it, it also does not turn into a cone hat, nor does it shrink as much as other caps do. When ordering, it is best to order a larger size than you might think fits so that when you wash it, it shrinks just enough to give you that comfortable, snug fit. Unlike other caps, this one doesn’t come in one size fits all; there are different size variations. 


  • The cap comes in different colors and beautiful designs
  • Material is strong and sturdy
  • It is oil-resistant and water-repellent
  • Convenient two-sided design
  • Offered in different sizes


  •  It shrinks slightly when you wash it

5. Miller Welding Cap

41WVYfHNcUL. SL500

For one of the most comfortable options on the market, get this cap from Miller Electric. They are known for many products, including welders, wire feeders, and welding safety equipment like helmets, safety glasses, gloves, fume extractors, caps, and many others. The company has been around since 1929 and has its headquarters in Appleton, Wisconsin. Many of their customers consider their products high quality, 0and it is no wonder one of their caps made it into our list.


The Miller welding cap is soft and comfortable to wear. Instead of the manufacturers using elastic material to make their products, they opted for sizing them out to ensure everyone gets a cap that fits as desired. Customers of this brand have popularized this cap for its durability. Most caps fail to stand the test of time and require care and proper maintenance.  This one, however, will withstand years of abuse and rough handling.

The cap has a low 6.5-inch crown with a reversible soft bill to offer fantastic flexibility. The manufacturer chose to go for 100 percent cotton in terms of material to increase comfort and make it breathable. When working, air will flow in and out, so you don’t get so hot and uncomfortable that it distracts you from your work.  

The cap weighs close to 1.5 oz, making it so light that users have reported forgetting it was on their heads when working. It might be a pretty decent hat with excellent qualities, but it is costly. Some people might not have a problem with this, but if you are on a budget, you should skip this one. You should also dismiss this one if you are looking for a cap that will cover your ears. However, should you decide to get it, you would be getting great value for your money as this cap is of excellent quality and will last a long time.    


  • Great overall quality
  • Comfortable to wear
  • Lightweight
  • Variety of sizes to give you a proper fit
  • Flexible courtesy of the reversibility option


  • Relatively expensive
  • It does not cover the ears


A lot goes into picking out a welding cap, whether it is your budget, function, or design preference. This list has given you some insights into the best welding caps. The Lincoln Electric cap with the American Print is the best overall welding cap we can recommend. It has a padded elastic ring, absorbs sweat, and has flat-stitched seams. In addition, it is also stylish and has a good design.  

The Miller welding cap is lightweight, durable, and of excellent quality, but expensive. The Revco welding cap is cheap and absorbs sweat, but it will only last for a while. If you were looking for a flame-resistant cap, the Bocomal welding cap would be your go-to, plus it is also stylish and elegant. The Welder Nation 8 is perfect for resistance as it handles ruggedness, and it is also durable.

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