Outdoor Hat & Headwear Buying Guide
Choosing the Right Outdoor Headwear
Outdoor headwear performs several different jobs depending on the conditions. It can provide insulation in cold weather, protect exposed areas from wind, keep rain or snow away from your head, or simply provide an extra layer that can be added and removed quickly.
A hat is also one of the easiest parts of a layering system to adjust. If you're becoming too warm during strenuous activity, removing your hat can help you cool down. When you stop or conditions become colder, putting it back on provides additional insulation without needing to change your main clothing layers.
The best type of headwear therefore depends on the weather, your activity and how much insulation you need.
Lightweight Thermal Hats & Balaclavas
Lightweight thermal headwear provides additional insulation without adding much bulk.
Thin beanie hats and balaclavas can be particularly useful for active pursuits where a thick winter hat would be too warm.
Their small packed size also makes them easy to keep in a pocket or rucksack as an additional layer if conditions become colder.
Sub Zero produces lightweight thermal headwear using the same principles as our performance clothing, providing insulation while keeping weight and bulk relatively low.
Wearing Headwear Under a Helmet
Thin thermal hats and balaclavas are sometimes worn underneath helmets for activities such as cycling, motorcycling and certain outdoor sports.
However, don't add headwear underneath a helmet if doing so compromises its fit or conflicts with the helmet manufacturer's instructions.
A helmet needs to fit correctly to provide its intended protection. Where under-helmet insulation is required, choose suitably thin headwear and check that it is compatible with the helmet being used.
Midweight Thermal Headwear
When conditions become colder, a midweight thermal hat or balaclava provides greater insulation than a lightweight version.
This can be useful for winter walking, outdoor work and other activities where you need additional warmth without moving to very bulky headwear.
Balaclavas provide considerably more coverage than conventional hats, protecting areas such as the ears, cheeks and neck depending on their design.
Neck warmers and tubes can also complement a hat by protecting the gap between your clothing and headwear.
Fleece Hats & Balaclavas
Fleece is widely used for cold-weather headwear because its structure traps insulating air while remaining relatively lightweight.
Thicker fleece hats can provide considerably more insulation than lightweight thermal headwear, making them useful during colder conditions or periods of lower activity.
Fleece balaclavas provide additional coverage for the face and neck and can be particularly useful in exposed environments.
The trade-off is additional bulk. A thick fleece hat that works well during a cold rest stop may become too warm during strenuous uphill activity.
This is why carrying more than one headwear option can sometimes be useful.
Windproof Hats
Wind can make exposed conditions considerably less comfortable, particularly around the ears and face.
A wind-resistant or windproof hat reduces the movement of cold air through the fabric and can therefore provide greater protection than a conventional knitted or fleece hat in exposed conditions.
Some designs concentrate windproof protection around the forehead and ears while retaining more breathable fabrics elsewhere.
Windproof headwear can be particularly useful for:
- exposed walking and hiking
- cycling
- winter outdoor activities
- outdoor work
- cold and windy everyday conditions
Knitted Hats & Beanies
The traditional knitted beanie remains one of the most versatile forms of cold-weather headwear.
Modern knitted hats can use a wide variety of fibres, including synthetic yarns, wool and merino wool.
Synthetic fibres such as acrylic can provide warmth with relatively simple care requirements, while wool and merino blends offer different combinations of insulation, moisture management and comfort.
Some knitted hats also incorporate fleece linings or additional insulation around the ears.
When choosing a knitted hat, consider whether you need something primarily for casual warmth or for more active outdoor use where moisture management and drying time may become more important.
Waterproof Hats
A hood isn't always the only option when it's raining.
Waterproof hats and caps use waterproof materials or membranes to provide protection from rain while leaving your head free to move independently of a jacket hood.
This can be particularly useful when visibility and freedom of movement are important.
Depending on their construction, waterproof hats may also provide wind protection and insulation.
For prolonged exposure to heavy rain, however, headwear should form part of an appropriate overall waterproof clothing system rather than being relied upon in isolation.
Balaclava, Beanie or Neck Warmer?
Different styles provide different amounts of coverage.
Beanie hats are simple, easy to carry and suitable for a wide range of cold-weather activities.
Balaclavas provide additional coverage around the face and neck and can be particularly useful in colder or more exposed conditions.
Neck warmers and tubes protect the neck and can often be pulled higher around the face when required.
Using separate pieces also provides flexibility. A beanie and neck warmer, for example, can be worn together in colder conditions and individually when less protection is required.
Choosing Headwear for Different Activities
For walking and hiking, choose headwear that can easily be removed and stored as your activity level changes.
For running and highly aerobic activities, lightweight, breathable headwear will normally be more appropriate than heavy insulation.
For winter walking and mountaineering, consider greater insulation together with protection from wind and exposed conditions.
For skiing and snow sports, make sure any headwear worn with a helmet is suitable for the helmet and doesn't interfere with its fit.
For outdoor work, durability and compatibility with required safety equipment may be as important as warmth.
For motorcycling, use only headwear compatible with the fit and instructions of your motorcycle helmet.
Headwear as Part of Your Layering System
Your hat, balaclava and neckwear shouldn't be considered separately from the rest of your clothing.
They're some of the quickest layers to adjust as your body temperature and the weather change.
If you're working hard and becoming too warm, removing or changing your headwear may be enough to improve comfort without removing a complete clothing layer.
When you stop moving, adding warmer headwear, gloves and an insulating layer can help you adapt quickly to the reduction in body heat being generated.
For that reason, compact headwear is worth considering even when conditions seem relatively mild when you set out.
Which Outdoor Hat Should I Choose?
Think about the conditions and activity rather than simply choosing the warmest hat available.
Consider:
- how cold the conditions are likely to be
- how strenuous your activity will be
- whether you'll be exposed to strong wind
- whether you need waterproof protection
- how much face and neck coverage you want
- whether the headwear needs to work with a helmet
- how small and light it needs to pack
For variable conditions, having two lighter options can sometimes provide more flexibility than relying on one very heavy hat.
The aim is the same as with the rest of your outdoor clothing: use the right amount of protection for the conditions and adjust it as those conditions change.