Best Welding Caps 2020 – Reviews & Buying Guide
Last Updated: August 3, 2020
Keeping your head and hair safe while you weld is important. You may have used an inferior welding cap in the past, and come to pay the price for your mistakes, whether it was through discomfort or singed hair.
We know that shopping online for things like welding caps isn’t always an easy task. It can be hard to compare different brands directly to each other, and if you ask your friends for advice, they’ll probably tell you it’s a personal choice.
A lot goes into the best welding caps on the market, and we want to ensure that you’re in the know, too. Our reviews are designed to show you why our choices are great, and why some traditionally popular picks aren’t all they’re made out to be.
Rundown of our Favorites in 2020:
|Best Overall||Lincoln Electric||
|Miller Ghost Skulls||
|Best Value||BSX Beanie||
|Lapco 6-Panel Caps||
The 7 Best Welding Caps:
1. Lincoln Electric Welding Cap – Best Overall
The Lincoln Electric Welding Cap (All American Print) is a great choice for welders who want protection, but who want to stand out, too. Under the bright colors are a series of comfortable and practical innovations that make it a product that will work for most welders. One of its most distinctive features is its padded elastic ring, which brings a lot of comfort to an area that many welders find troublesome. Likewise, the flat-stitched seams won’t rub or get caught in your hair, making this one of the best welding caps on the market in that regard.
It also comes with a sweat-absorbing liner, which helps keep you cool, even when things get hot. And while you might worry about it getting soaked, it’s made from breathable fabric, which helps keep you cool and dry. While this model fits most people, it does suffer from inconsistent sizing, leading some people to get caps that are too small or large. This is a one-size-fits-all product, so people with large or small heads may want to opt for a different cap. Still, if you’re looking to make a statement and keep cool, this is the welding cap for you.
2. Miller Ghost Skulls Welding Cap
While there’s little that could make someone brave welding without a welding cap, an uncomfortable welding cap would make some people second-guess their choice. Luckily, the Miller Genuine Arc Armor Ghost Skulls Welding Cap is easily one of the most comfortable caps on the market. With its soft cotton material and its use of sizes instead of elastic, it’s one of the best products you can choose for comfort. Even better, this cap has a reputation for durability. While not every welding cap will last through years of use and abuse, this brand is known for going the distance.
Since this cap comes in different sizes, you can get the one that best fits your head. That means there’s no elastic to bother your head, and you should get a good fit if you get the right size. It only weighs 1.44 ounces, which makes it so light that you’ll hardly notice it while you’re wearing it. However, it comes at a high price, which isn’t unexpected for a model of this quality, but that’s enough to hurt its value. If the price were to go down, we could rank this cap in the top spot.
3. BSX Welding Beanie – Best Value
The BSX Gear BC5B-BK Welding Beanie is a great choice for most people looking for a welding cap. For one, it’s incredibly lightweight. At just .64 ounces, this isn’t a cap that most people will feel encumbered by while they weld. Plus, it’s breathable, so your head will stay cool even as your surroundings get hot. This cap also runs slightly large. That means it’s great for people with above-average heads, since it will fit them perfectly. It also shrinks in the wash, so it can be adjusted for use by those with smaller heads.
However, the thing we like best about this cap is that you can get it for a fraction of the price of the top two on our list. While you’re unlikely to wear it out quickly, you could buy a replacement and still spend less than what you would have to spend on other welding caps. That makes this cap the best overall choice for the money here. However, you do have to keep in mind that it shrinks if washed. If you’re careful, you’re sure to really enjoy what this cap provides for the price.
4. Comeaux Reversible Welding Cap
There are a lot of things to like about the Comeaux Caps Reversible Welding Cap. It’s reversible, so you can keep the best-looking side out if you so choose. It’s also sized, not one-size-fits-all. You should be able to get a good fit, whatever your head size, as long as you order the correct size. It’s made from cotton and is very breathable, so hot air and moisture won’t get caught under it. This helps keep you cool and dry while you work.
Another thing we love about this cap is that it’s really consistent from a quality standpoint. The stitching, sizing, and material quality doesn’t vary from order to order, so if you ever have to replace it, you’ll be sure to get another just like it. The one thing we don’t like is that it can sometimes be stiff on arrival. It needs a wearing or two, and possibly a wash, before it starts to feel really comfortable. If it were better in that area out of the box, we could easily bump it up into the top three. This is a cap that most people will enjoy wearing.
5. Lapco 6-Panel Welding Caps
The Lapco FR Lap CC-7 1/4 6-Panel Welder’s Caps is a line of caps that does a number of things well. For one, many people will love the camo design. While few people will be hunting with their welding masks on, it does make for a neat aesthetic. But if it isn’t your aesthetic, it still brings some value as the camouflage will make dirt and grime harder to see in many instances. It’s made from cotton, so it’s a very breathable fabric. This model is also stitched together with Nomex thread, which is flame-retardant.
Unfortunately, this cap weighs more than two ounces. That’s heavy for a welding cap, the lightest of which can weigh a fraction of an ounce. While two ounces isn’t objectively heavy, if you’re used to lighter welding caps, you’ll notice while you’re using it. Given its extra heft, it’s hard to justify the relatively high price these caps command. Most people will like wearing them, but the bad news is that most people will be able to get better value for their money.
6. BSX Black/Blue Welding Cotton Beanie
The Black Stallion BSX BC5B-BLU Black/Blue Cotton Beanie certainly isn’t the worst welding cap on the market, but there are many reasons users will be better off with a different one. On the plus side, this cap is explicitly labeled flame-retardant, which is a good thing to have when you’re welding. It’s reasonably breathable, though it doesn’t have as many great sweat-absorbing or other sweat-wicking properties. It’s also very lightweight. At just .32 ounces, it’s so light that even people used to lightweight welding caps will notice how light it is.
However, it might be too light. Some users describe this cap as “paper-thin,” which isn’t necessarily a good thing. That means it can get uncomfortable throughout the day, and thinner caps won’t stand up as well to use as thicker caps. This cap is more likely than most to wear out fast. It also tends to run small, which can be an issue. Ultimately, this is a welder’s cap that most people won’t like very much, making it a bad deal regardless of price.
7. Revco Cotton Welding-Cap
The Revco Armor Cotton Welding Cap (C5W-BK) has an interesting look, but it won’t make most people happy. It is a thicker cap, so it doesn’t have the problem of the previous model. It also has some sweat-wicking properties, so if you have any problems with discomfort, they’ll come from other areas. Sadly, this cap suffers from multiple problems that limit its comfort. It doesn’t always come with a great shape, which can make it pinch and pull in certain areas. The stitching isn’t always done correctly, which can make it rub or be scratchy. Worse, the elastic tends to be very tight, which leaves a lot of workers sighing for relief when they take it off.
This cap doesn’t have great durability, either. Regular washing will render it a threadbare version of itself, which means it can only last so long. It also tends to run small, which is a huge issue in combination with the fact that it already comes with tight elastic. Overall, there’s not a ton to like about this model. Despite its low price, most people will be able to get better value with a different cap.
The Lincoln Electric Welding Cap (All American Print) is our favorite welding cap due to its padded elastic ring, sweat-absorbing material, and flat-stitched seams. The Miller Genuine Arc Armor Ghost Skulls Welding Cap is comfortable, durable, and lightweight, but its high price costs it the top spot. The BSX Gear BC5B-BK Welding Beanie is extremely lightweight and breathable, and its great price makes it the best overall value. Fourth place belongs to the Comeaux Caps Reversible Welding Cap, which comes in different sizes and is consistently well-made, though it needs some breaking in.
In fifth, the Lapco FR Lap CC-7 1/4 6-Panel Welder’s Caps line has a cool camo design, breathable fabric, and Nomex thread, but they’re heavy and pricey. The Black Stallion BSX BC5B-BLU Black/Blue Cotton Beanie is flame-retardant, breathable, and very lightweight, but its thin material won’t hold up well to frequent use. Last place goes to the Revco Armor Cotton Welding Cap (C5W-BK), which has thick, sweat-wicking material. However, its poor durability, sizing inconsistency, and general lack of comfort make it a poor overall choice.
We hope that our reviews have helped you think through which welding cap is right for you, and given you the information you need to buy the cap that will keep your head cool and safe.
Related reads: an overview of the different types of welding helmets
- Rundown of our Favorites in 2020:
- The 7 Best Welding Caps: