When standard, off-the-shelf washers don’t meet your application requirements, non-standard washers are the solution. Whether you’re dealing with unusual dimensions, specialist materials, or tight tolerances, these components are custom-made to do what standard washers can’t.
As a leading non-standard washers supplier, Stephens Gaskets provides tailored solutions for engineers, manufacturers, and designers who need precise performance without compromise. In this blog, we’ll explain what defines a non-standard washer, where they’re commonly used, and how our washer manufacturing service helps solve problems across industries.
What Are Non-Standard Washers?
Non-standard washers are components that fall outside typical size ranges, shapes, tolerances, or materials. They are usually custom-designed to suit unique engineering requirements that standard washers simply can’t address.
These variations may include:
- Unusual inner or outer diameters.
- Non-circular shapes (D-washers, square, tabbed, slotted).
- Custom thicknesses or step profiles.
- Special materials like PTFE, Inconel, fibre, or plastics.
- Tight tolerances for high-performance assemblies.
They can be manufactured to exact drawings, CAD files, or even physical samples, allowing for complete design freedom.
When Do You Need Non-Standard Washers?
You should specify non-standard washers when:
1. You’re Working with Non-Standard Fasteners
If your bolts, screws, or fittings are non-metric, oversized, or undercut, you’ll need washers to match.
2. Your Application Requires Tight Tolerances
Standard tolerances often don’t cut it in high-precision machinery. Bespoke washers UK engineers specify allow for better alignment and reduced wear.
3. Environmental Conditions Are Extreme
Heat, chemical exposure, pressure, or movement can degrade standard materials. Non-standard washers can be tailored from materials built to withstand these conditions.
4. Space or Weight Is a Constraint
In aerospace, electronics, or compact mechanical systems, every millimetre counts. Custom shapes and thicknesses provide the exact fit required.
5. You’re Restoring or Replacing Legacy Parts
Older machinery may rely on odd size washers that are no longer commercially available. We can replicate or redesign these from a sample.
Industries That Rely on Custom Washer Manufacturing
As an experienced non-standard washers supplier, we serve a broad range of sectors, including:
- Aerospace and defence
- Automotive and motorsport
- Industrial machinery and OEMs
- Medical device assembly
- Electrical and electronics
- Plumbing and HVAC installations
From high-load flanges to delicate circuit spacers, non-standard washers are essential for performance, safety, and longevity in critical assemblies.
Our Washer Manufacturing Service
Stephens Gaskets provides a fully flexible washer manufacturing service, offering:
- Thicknesses from 0.05mm to 10mm+
- Custom OD/ID configurations
- Material choice from 100+ metals and non-metals
- Profile types: slotted, chamfered, tabbed, stepped, and more
- Small batches, one-offs, or high-volume runs
- Manufacturing to drawing, sketch, CAD, or sample
Whether you’re in R&D or volume production, our team delivers bespoke washers UK-wide with consistent quality and support.
See the washer itself or learn more about our washer manufacturing service for technical detail and ordering guidance.
Why Choose Stephens Gaskets?
With over 70 years of industry experience, Stephens Gaskets is a trusted non-standard washers supplier committed to accuracy, speed, and support.
We offer:
- UK-based ISO 9001-certified manufacturing.
- In-house CAD and prototyping services.
- Fast turnaround and flexible order sizes.
- Advice on material selection and tolerancing.
- Proven supply for OEMs, repair engineers, and R&D teams.
From concept to delivery, we manufacture washers that do exactly what you need—without compromise.
When to Specify Non-Standard Over Standard
Choose non-standard washers when:
- Standard washers don’t fit properly or function reliably.
- The environment is harsh, high-temperature, or chemically aggressive.
- Your assembly involves unique fasteners or fittings.
- You need odd size washers for legacy parts.
- You’re building something innovative or highly technical.
Our washer manufacturing service ensures your components are made precisely, perform perfectly, and arrive on time.
Frequently Asked Questions
1. What file types do you accept for custom washer designs?
We work from DXF, DWG, PDF, and hand-drawn sketches. We can also reverse-engineer from a physical sample.
2. Can I order one washer or do I need to buy in bulk?
We offer full flexibility – from single prototype parts to thousands of units.
3. What materials can you produce non-standard washers in?
Metals like stainless steel, aluminium, brass, copper, Inconel, and non-metals like rubber, PTFE, nylon, fibre, and composites.
4. How quickly can I receive my custom washers?
Lead times vary by complexity, but we typically offer dispatch within 3–5 working days, with express options available.
Final Thoughts: Custom Washers for Custom Challenges
Off-the-shelf parts won’t always meet your technical needs—but non-standard washers from Stephens Gaskets will. Whether you’re solving a tolerance issue, sealing against vibration, or matching a legacy system, we provide the expertise and manufacturing agility to support your success.
Trust us as your bespoke washers UK partner – we’ll machine the washer you need, not just the one that’s available.