How To Measure Welding Cap Size? Step by Step (with pictures)

How To Measure Welding Cap Size? Step by Step (with pictures)

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Welding caps are an important part of personal protective equipment. As a person engaged in the process of welding, it will not only be helpful to wear this helmet when you are involved in the welding, but it can also be worn if you are around other people who are welding so the head will be protected from flying sparks.

The size of the welding cap is determined by the amount of protection it provides. There are three common types of welding caps: full-face, half-face, and open-face. Each type has different features that make it better suited for certain types of welding work.

How To Measure Welding Cap Size? Step by Step (with pictures)

Full-face welding caps are the most popular type because they offer the most protection. They cover the whole of the wearer’s head except for a small opening in the front for breathing.

Half-face welding caps cover only the front part of the head, and open-face welding caps leave the entire head exposed.

All three types of welding caps come in different sizes to fit different heads. The size of a welding cap is measured in millimeters (mm).

How To Measure Welding Cap Size?

How To Measure Welding Cap Size?

Welding caps come in all different sizes, so it can be difficult to determine which one is right for you.

Here Is How To Measure Welding Cap Size:

Step 1:

Use your cloth tape measure to measure the distance between the middle of your forehead and the end of the tape. A piece of string is a good substitute for a metallic tape measure if you are using one.

How To Measure Welding Cap Size? Step by Step (with pictures)

Step 2:

You should wrap the tape or string around your head until you return to the beginning. It should rest at the point where the hat should rest above your ears.

How To Measure Welding Cap Size? Step by Step (with pictures)

Step 3:

Ensure you have a snug fit with the tape measure or string around your head, but not too tight. Your headband should be comfortable, but snug enough so that it stays in place.

How To Measure Welding Cap Size? Step by Step (with pictures)

Step 4:

Make sure you write down your measurement in inches. If you are measuring the string with the tape measure, make sure to take note of the measurement in inches.

Step 5:

You can use the size chart above to determine what size will be most suitable for you. It is recommended that you go up one size if your size is in between.

Infographic Guide

How To Measure Welding Cap Size? Step by Step (with pictures) infographic guide

What Are The Benefits Of Using A Welding Cap Correctly?

There are many benefits to measuring your welding cap correctly. Inaccurate sizing can lead to improperly fitted welding caps, which could cause your arc welder to work less efficiently and produce lower-quality welds.

Additionally, improperly fitted welding caps can also cause leaks or even damage to your equipment. By following the guidelines below, you can ensure that your welding cap is both correctly sized and fit for your equipment.

Finally, using a proper welding cap can enhance your safety while welding. By ensuring that your welding cap is properly fitted and sized, you can avoid potential injuries while working.

Our Video Guide on How To Measure Welding Cap Size?

Final Words

If you’re looking to buy a welding cap, it’s important to know the right size for your needs. Never buy a welding cap that is too small or large. A welding cap should fit snugly on your head, but not so tight that it’s uncomfortable.

Where To Get Welding Caps?

We want to make sure you also stay up to date with everything in the best welding caps on the market, so here is the best welding caps comparison chart.

In our reviews of the best welding caps, we will explain why our selections are the best and why some traditionally popular choices are not the best.


Hi, I’m Andrew Miller — a certified welding expert and instructor based in Long Island, NY.

With over three decades in the industry, I’m passionate about combining theoretical knowledge with hands-on experience to train the next generation of skilled welders.

I specialize in all forms of arc welding, including GMAW, GTAW, GMAW, FCAW & SAW. But my experience isn’t limited to just those—I’m also knowledgeable in oxyfuel gas welding and plasma arc cutting.

My years as a welding inspector and supervisor have honed my ability to ensure the highest standards in welding quality and safety, making me adept at executing and overseeing complex welding operations.

You can find more information about me on my website,, or connect with me on LinkedIn.

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