As a leading UK manufacturer of custom aluminium shim washers, Stephens Gaskets understands the critical role these components play in high-precision engineering. Whether you’re in aerospace, automotive, electronics, or general manufacturing, getting the thickness and tolerances right is essential for optimum performance and longevity.
This guide offers practical advice on choosing the correct shim washer thickness and tolerance. It’s crafted to assist engineers, purchasing managers, and design specialists in making confident, informed decisions. We’ll cover typical applications, standard thickness ranges, how tolerances affect performance, and why bespoke solutions like custom aluminium washers matter more than ever.
Why Thickness Matters in Aluminium Shim Washers
Choosing the right thickness isn’t just a technical decision – it’s a performance and reliability issue.
Aluminium shim washers act as precision spacers. They help align components, compensate for wear, and reduce vibration or thermal expansion. Selecting an incorrect thickness can cause mechanical failure or reduce the system’s efficiency.
Thicker washers provide structural stability. Thinner ones are ideal for micro-adjustments in finely tuned systems. Knowing when and how to use each ensures optimal engineering performance.
Standard Thicknesses Available
At Stephens Gaskets, our aluminium shims cut to size come in a wide range of standard and bespoke thicknesses.
Common stock sizes include:
- 0.05mm to 3mm for general engineering
- 0.01mm increments available in high-tolerance ranges
- Custom thicknesses available on request
We use high-grade aluminium alloys like 1050A, 5251, and 6082, which are known for their excellent formability, corrosion resistance, and strength-to-weight ratio.
How to Select the Right Thickness for Your Application
Selecting the correct thickness depends on several variables. Here are key factors to consider:
1. Load Requirements
If your shim will carry weight or pressure, a thicker washer (1mm and above) might be necessary. These are commonly used in automotive and heavy-duty machinery.
2. Precision Alignment
For ultra-precise assemblies, thinner washers in the 0.05mm to 0.5mm range are ideal. This is often the case in aerospace, electronics, or medical devices.
3. Thermal Expansion Compensation
Aluminium has a relatively high coefficient of thermal expansion. Thinner shims are more flexible, allowing for better thermal compensation where temperature fluctuation is an issue.
4. Assembly Tolerances
A precise fit between parts ensures reliability. Tight tolerances mean you need exact thicknesses, which is where bespoke aluminium washers shine. They allow you to build or repair with millimetre-level accuracy.
Understanding Tolerances
Tolerances are the allowable limits of variation in a washer’s thickness. They determine how consistent your parts will be. Even a 0.01mm variation can cause misalignment in precision systems.
At Stephens Gaskets, we manufacture precision aluminium washers to strict ISO and BS standards, offering tolerances as tight as ±0.01mm on request. This level of detail ensures every washer fits perfectly, every time.
The Benefits of Custom Aluminium Shim Washers
Not all jobs fit a standard washer. That’s why we specialise in custom aluminium shim washers designed for unique applications.
Customisation allows:
- Non-standard diameters and thicknesses
- Specific alloy selection
- Tight tolerance control
- Special coatings or treatments
This tailored approach ensures optimal fit and function while reducing downtime and assembly errors.
Need a washer tailored to your drawing?
Our engineering team will manufacture aluminium shims cut to size, exactly to your blueprint or sample.
Explore our full range of custom aluminium washers and bespoke aluminium washers to discover what’s possible.
Use Cases: Where Aluminium Shim Washers Excel
Automotive
Used in engine assemblies, braking systems, and gearboxes for precise part alignment.
Aerospace
Ideal for light-weight, high-strength applications. Precision is key, especially in turbine engines and structural assemblies.
Industrial Machinery
Used for levelling, spacing, and adjusting moving parts to avoid wear or misalignment.
Electronics
Where compact and exact spacing is needed, such as in PCB mounting or housing assemblies.
Common Mistakes to Avoid When Selecting Shim Washers
Even seasoned engineers sometimes fall into common traps when choosing shim washers.
Here are key mistakes to avoid:
- Ignoring Thermal Expansion: Aluminium expands under heat. Don’t overlook this when designing for high-temperature environments.
- Choosing Based on Price Alone: Lower-cost washers may not meet tolerance specs, leading to costly rework.
- Underestimating the Role of Fit: A loose or tight fit can impact performance. Always measure twice, specify clearly.
- Skipping Custom Options: If your application is unique, a bespoke aluminium washer is usually the smarter long-term solution.
Why Choose Stephens Gaskets?
With over 70 years of experience, Stephens Gaskets is a trusted UK manufacturer of custom aluminium shim washers. We are ISO 9001-certified, and our in-house team uses advanced CNC and laser cutting for unmatched precision.
From prototyping to large-scale production, we deliver shim washers that meet the exact specifications of each customer. We also offer next-day delivery for many of our aluminium shims cut to size, making us a dependable partner in time-sensitive industries.
Frequently Asked Questions
1. What thicknesses are available for aluminium shim washers?
We supply shim washers from 0.05mm to 3mm as standard, with bespoke sizes available upon request.
2. What tolerance can I expect?
Our manufacturing processes ensure tolerances down to ±0.01mm, depending on the material and thickness required.
3. What’s the lead time for custom sizes?
Standard lead times range from 3-5 working days. Urgent jobs may be accommodated through our express service.
4. Can aluminium washers handle load-bearing applications?
While aluminium is lightweight, it’s suitable for moderate loads. For heavier applications, we recommend evaluating alloy selection or considering multi-layer shimming.
Final Thoughts: Precision Matters
Choosing the right thickness and tolerance for your aluminium shim washers is not just a technical step – it’s a strategic one. It ensures better assembly performance, improved longevity, and fewer faults.
When you work with Stephens Gaskets, you get more than just a component. You get a manufacturing partner that values precision, quality, and service.
Whether you’re sourcing standard items or need a completely bespoke aluminium washer, we’re here to help you specify, source, and succeed.
Ready to Specify Your Custom Aluminium Shim Washers?
Let our team help you find the perfect solution.
Whether you need a standard thickness or a fully customised spec, we’re here to support your project from start to finish.