You can order the size closest to your measurement. Cotton fabric naturally has some flex. Or, you can request a custom measurement in the Text Box on each product page.

Cap Depth is how far down the cap fits over ears and forehead. Everyones' fit preference is different and I have several standard options to choose from. You can also choose a custom depth if you prefer. You can find all the details on this Size Measurements Page > Size, Depth & Brim Measurements

Brim Depth is personal preference.

The 2 1/2" depth started as the Standard depth for a 1 size fits most.
Later I added the 2" based on Customer Requests and then the 3" for more coverage.
If you have a cap with the perfect brim you can measure it. Fold the brim in half to find the center (left/right) and measure from where thek brim attaches to the cap to the edge if the brim.

Sometimes 'Good Enough' isn't. You need a good fit, and what fits one person well might be wrong for the next guy. If you're going to get a Custom Welding Cap you should get as much customized to fit You as possible. I can do that and you have 4 standard depth options from 6 1/2" to 8" to give you the best choice possible.
Custom depth measurment requests can also be sent in the Custom Measurements text box on each product page.

Absolutely! That's exactly why I use high quality quilting style cottons in both print and solid colors. You may have to adjust the welding hood or hard hat fit harness for caps with a cotton or microfiber sweatband as the bands of caps with sweatbands are slightly thicker than welding caps without sweatbands.

Absolutely! HDWH customers wear their caps under not only welding hoods, but hard hats, motorcycle helmets and welding caps alone.

Absolutely! You can find the size chart on the page linked below, and sizes are matched with measurements on the every product page.

Size, Depth & Brim Measurements

When FR denim became available via my supplier it was a 'no brainer' decision to go ahead and use it instead of regular denim or the quilt batting other makers use. FR Denim in the brim, often the most exposed area of the cap is the right choice. No question about it. Keep those sparks off your ear and neck as much as possible, no burn through.

Yes. Cotton is selected because it is durable, breathable, flexible, comfortable, machine washable, and does not melt when exposed to heat like many synthetic fabrics.

All the welding caps are made in my shop in Central Oregon.

Yes, every welding cap is made for each specific customer. I use their measurments, fabric choices and any add on requests. There are no premade caps in the shop for purchase.

HD Welding Hats are made for everyday use in demanding welding environments. With proper care and laundering, many customers enjoy using their welding caps for years. How long a cap lasts depends on the type of welding, working conditions, and how often it is worn and washed. Many of my regular customers purchase new caps about once a year, often adding new fabrics while keeping their older favorites in rotation.

I suggest machine washing with like colors in hot or cold water - which ever is your preference with your favorite laundry detergent. Use color safe bleach on colors if you wish.
Hang drying is recommended because it keeps the cotton fibers more flat and less likely to catch sparks. If you machine dry, you can also use spray starch on the brim and press with an iron to flatten the fibers.

Chlorine bleach for solid white hats is recommended when needed.

No specail care is required.

They shouldn't. In fact, I have not had anyone tell me their welding caps shrunk. That being said - get the size your measurements show you need - DO NOT size up for shrinkage. The caps will not shrink a size.
I pre-shrink in hot water wash, high heat dryer and press multiple times thru the production process - the fabric has been heat treated multiple times.

Yes, on every welding cap product page there is a text box for Custom Measurements, Lining colors and other requests.

Yes, most hats will have the option for embroidered text on the band. If you need something else please reach out before ordering.
There is a 6" wide area for text on the band, the more letters and spaces the smaller the text will be to fit in the space.

Embroidery is an additional cost.

Yes, most hats will have the option for sweatbands, both cotton and microfiber.

The sweatbands are placed inside the band of the cap for comfort - the cotton sweatband is not as soft as the cotton fabrics, and the microfiber is so absorbant is can dry out the skin with prolonged exposure.

Sweatbands are an additional cost.

Kevlar thread is an incredibly strong, heat-resistant, and flame-retardant thread used for high-stress, high-friction, and high-temperature applications. It is roughly 2.5 times stronger than nylon/polyester, features almost zero stretch, and decomposes around 800°F (426°C).

It is used on the brim as reinforcement stitching and on the botton edge of the band that receives the most wear.

I always suggest trying at standard cap with no extras to experience fit before adding extra features.

Yes, I carry about a dozen different colors of solid colors in flannel for winter wear caps. The flannel is in the crown section only, not the band or the brim.

Yes. If you have an idea or would like something that's not listed on the website, feel free to reach out before ordering. I'll let you know whether it's something I can make with my current materials and equipment. While I can't accommodate every request, I'm always happy to discuss the possibilities.