Best 5 Welding Caps in 2021 – Reviews, Top Picks & Buying Guide

Better safe than sorry! It is essential to keep your head and hair safe while you weld on any metal. You can never be too safe and careful while welding as a lot of spatter and slag production occurs while welding. Your head requires the most attention and protection than any other body part.

As we have been talking about our heads a lot, we are providing you some best yet affordable choices to get your first welding cap. You might find it silly to get welding to cap that to something that is just like a thin layer of clothing. Looking at all the benefits and features that the best welding caps given below offer you will make you understand its importance.

Overall Best Pick

Revco REVCO - BC5W-BK Armor Cotton Welding Cap, 100% Cotton...
2,552 Reviews
Revco REVCO - BC5W-BK Armor Cotton Welding Cap, 100% Cotton...
  • Bc5w-bk bsx armor cotton welding cap, 100% cotton double layer protection
  • Welding cap, doo rag and beanie - all in one
  • One size fits all
  • Package dimensions : 1.0 inches (H) x 5.0 inches (L) x 4.0 inches (W)

The Budget Pick

Lincoln Electric Welding Cap| Mesh Inside Liner | All...
1,534 Reviews
Lincoln Electric Welding Cap| Mesh Inside Liner | All...
  • HIGH QUALITY COTTON – Made from soft, high thread count cotton and features a stylish stars and stripes fabric...
  • SWEAT ABSORBANT LINER – The inside of the Welders Cap is lined with a soft athletic mesh which absorbs moisture and...
  • FLAT STITCHED SEAMS – To prevent discomfort from seams from pressing / rubbing against the forehead, the welders cap...
  • LIGHTWEIGHT & BREATHABLE - The 100% cotton material is breathable by design. This allows consistent airflow to keep you...
  • ELASTIC FIT – This headwear features an air cushioned elastic band which stretches to fit the users head dimensions.

1. Lincoln Electric Welding Cap

Welding fume extractor

With all the blue sketchy designs on this welding, the cap gives you a lot of the vibes from ‘Captain America’ and his cap. Lincoln in general has been manufacturing top-notch and affordable welding equipment and gear over the past decade giving its customers that satisfaction of their purchases.

It is made completely out of cotton and is one of the most comfortable welding caps available in the market. It has a mesh liner inside it that helps facilitate the passage of air and prevent heat build-up and pressure. Even if you sweat a ton, this liner is made out of absorbent material and will absorb sweat easily.

Padding is provided to ensure the ideal amount of comfort for the user. The elastic ring provided will help you have a snuggly, perfect fit. You can believe in Lincoln products for their reputation and the quality of service that they provide.



ManufacturerLincoln Electric – Welding Gear and Tools
Item Weight1.12 ounces
Package Dimensions6 x 1 x 1 inches
Item model numberK3203-ALL
Part NumberK3203-ALL
SizeOne Size
Item Package Quantity1
Measurement SystemUS


  • An affordable welding cap with a ton of quality and features to offer.
  • High-quality cotton material with Kevlar thread stitching.
  • The mesh liner absorbs the maximum amount of heat and sweat from your head. Flat-stitching in the seam helps us maintain comfort throughout its use.
  • The fit is adjustable and fits almost any kind of head size.
  • You can wash it with ease and never wears out even though you may use it regularly.
  • The smooth exterior makes the welding helmet to fall off sometimes.

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2. Welder Nation 8 Panel Welding Cap

Welding fume extractor

This welding cap made by ‘Welder Nation’ is a highly-affordable welding cap costing around $20-$25 and is made out of high-quality 10 oz. cotton canvas. This is truly durable and built-to-last for a very long time. This type of material is generally used in jackets, coveralls, and overalls.

It has an 8-panel innovative pattern with cross-stitches and threads that never wear off. The exterior of the cap is made out of duck canvas with cotton lining on the inside. It has 10 sizes available to the customers with over 6 different color schemes. It has been tested with wear and tear and is known to withstand very harsh conditions.

  • It is made out of 100% cotton making it highly comfortable to wear and it is easy to clean.
  • This welding cap has a deeper crown and is much more effective than other welding caps out there.
  • It has good pricing and is quite affordable. According to the people who have used this for over a year and their reviews, it sure is a quality product with minimal flaws.
  • Washing is multiple times is necessary to remove excess sweat that is contained inside of it.

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3. Revco – BC5W Armor Cotton Welding Cap

Welding fume extractor

The design and the shape of this welding cap might look like it does not have much to offer. This welding cap from ‘Revco’ has some amazing features to offer for its welders. It is made out of 100% cotton and has double-layer protection. This prevents the intrusion of spatter and slag production.


  • 100% cotton double layer protection.
  • Welding cap, doo rag, and beanie combo.
  • One size fits all.
  • Package dimensions: 1.0 inches (H) x 5.0 inches (L) x 4.0 inches (W).
  • Imported from the USA.
  • Color: Black
  • In this list of welding caps, this model from this reputed brand is the cheapest of them all.
  • Even though this cap offers just a single free-size, no one finds it hard to fit their heads.
  • The elastic lining helps it a perfect fit for small as well as large heads.
  • The double-insulated layer helps prevent heat accumulation and damage done to the head.
  • It has a cool- yet subtle design making it suitable for work.
  • It lacks certain water and fire-resistant properties.

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4. Miller Genuine Arc Armor Welding Cap

Welding fume extractor

Miller is another reputed brand in the welding industry producing welding gear and equipment as efficient and built-to-last giving a great competition to ‘Lincoln Electrical’. It has good flame-resistant properties and is one of the best. It is available in various sizes ranging from 6 ¾ – 8 inches giving you a wide range of fit options.

It is completely made out of cotton and has a 6-panel construction. It is completely breathable and prevents heat from building up. This cap is ideal for working in the summer season or where the air supply is limited in the workplace.



ManufacturerMiller Electric
Item Weight1.44 ounces
Package Dimensions6 x 1 x 1 inches
Item model numberFBA_230543
Is Discontinued By ManufacturerNo
Item Package Quantity1


  • It is made from 100% cotton making it highly breathable and comfortable for regular use.
  • It has 6 ½ inches of the crown and has a soft bill.
  • It is reversible making it easy to swap sides and use if you have already used one side previously.
  • It’s already been pre-shrunk, hence you will find it shrink furthermore due to washing.
  • The fabric is of top-quality and hence will not deteriorate over time.
  • It is tad more expensive than the other welding caps.

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5. Comeaux Reversible Welding Cap

Welding fume extractor

This Comeaux top arrives in an advanced strong dark shading. It has 6 boards and is made of unadulterated cotton. It has a delicate edge and is reversible. It is medium-delegated so as to cover the welder’s ears and neck.

This is made with incredible planning and there is no failure once you buy. Comeaux is unquestionably an industry chief. Estimating 7 and 1/4 crawls from the crown’s top to the top’s base, this welding top offers a decent measure of inclusion. It additionally includes 6 boards for a superior and a progressively all-inclusive fit. The delicate edge configuration guarantees that you can wear this for quite a while without the distresses that regularly happen when the edge is excessively close.

This top, just as the various tops made by Comeaux, have experienced twofold assessment, along these lines guaranteeing quality. The medium crown configuration likewise gives a superior degree of security and can likewise work in ensuring the neck and ears, not at all like other welding tops.



ManufacturerComeaux Caps
Item Weight2.39 ounces
Package Dimensions6 x 10.1 x 1.65 inches
Item model number20712black
Part Number118-2000R-7-1/2-BLK
Is Discontinued By ManufacturerNo


  • Reversible wear making it a cool product
  • Free-sized and made with breathable cotton
  • Consistent production

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The first welding cap comes from a story where a welder was constructing a boiler at a great height and fell down and he died just because he has no protection to his head. The welding crew repaid the widow that helped her out in the needy time. So, she was very grateful to them and gifted them caps for welding. She only had scraps of different materials with varying colors and designs.

The men accepted her generosity and accepted the caps as they were and started using them during welding every day. Over time, the welding crew understood that those designs on the cap helped them welding more peacefully without any interruption due to sparks and slag coming from the weld. Hence, they began paying the widow some money to get more of these so-called ‘welding’ caps.

This design has been around for several decades with a small twist to people’s preference in today’s world many sewing shops and moms at home make these caps. The basic design is still kept intact after all these years too. Kromer’s caps are very similar to that of these welding caps and have been sold since the 20th century.

Buying Guide to best welding caps

Welding caps are made up of 100% cotton. Nylon isn’t ideal for manufacturing welding caps as it catches fire quite easily. Since these are made out of cotton, after rewashing, they shrink easily. Getting a bigger size is always recommended.

Purpose of High-Crown Welding Caps
Welding caps are generally snuggly when you wear them for the first time as it has a crown protruding on your head like a mountain. If it fits your head well, then it will be really comfortable to wear even it takes time to get used to the look. It is a time-saver if you use these welding caps during your welds. If you are welding at an odd position, then you can easily pull the welding cap to the side of the ear to cover your ear with the bill turned to cover the ear on the high side.

When the welding cap is pulled really low, more head area can be protected while welding from hot sparks and if you have hair, it can be really helpful. Overhead welding is a really hard process and tedious in more ways than you can imagine. A welding cap with the bill to the back can help you protect yourself and your clothes from sparks and debris falling over you.

Short, Floppy Bill Caps
A soft and attractive little bill is easier to fit under the welding hood than your regular ball cap bill. If the bill is too long or stretched to be worn by many now, it can be difficult to fit under a welding helmet. Having a small bill with a slight downward angle makes it easier to protect the ears and neck.

Welding caps can be customized in many configurations. An option as long and tough a bill as a short crown. My suspicion is that these are more for casual wear than actual work. You can wear them for cold weather and comfort.

Frequently Asked Questions :

1.What are welding caps for?
Welding caps are used to absorb the sweat that we produce while welding, protect our clothing, and head from damage due to spatter production, and reduce heat intake from the surrounding workplace.

2.What are welding caps made of?
Welding caps are made up of 100% cotton generally for absorbing all the sweat we produce providing us immense comfort with the inner mesh lining. The outer layers are made up of duck covers making them sturdy and durable.

3.How do you size a welding cap?
Your head circumference can be measured using a fabric measuring tape where you generally wear your ball cap around the brow bone region. The size chart available with the product description can help you choose the cap according to this size you have measured.

4.Why do welders wear bandanas?
A bandana is worn by welders usually as it helps protect their forehead from extra sparks and spatter falling out while welding.

5.What type of welding is the hardest?
According to many researchers and experienced welders, Tungsten Inert Gas Welding (TIG) is considered to be the hardest form of welding. This is because there a lot of welding parameters to be remembered, and it being a tedious process, it is time-consuming and challenging to master.