Best Welding Caps of 2021 – Reviews & Top Picks

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 2020.

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 - 2021

1. 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.

2. 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.

3. 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.

4. 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.

5. 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.

How To Choose Welding Caps

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 3 months by Richard Boyer

  • January 21, 2021
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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