Screwdriver Size Chart: Phillips #0-#4, Flathead & Torx (mm)
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Screwdriver sizes are measured by tip width in millimeters, with Phillips heads running #00 (smallest) to #4 (largest) – but Torx and hex sizes follow a completely different numbering system. Using the wrong size strips the screw head or slips off mid-turn, ruining both the fastener and the surrounding wood. This guide covers Phillips, flathead, Torx, and bit sizes with verified dimensions, so you can match any screwdriver to any screw.
Quick Answer
Most household screws use a #2 Phillips or a 1/4″ (6mm) flathead – these are the “standard” sizes. Electronics and small hinges usually need #0-#1 Phillips, while deck and construction screws often take Torx (T15-T25) or square-drive bits. Match the bit to the screw head so it sits flush with no wobble before applying torque.
Understanding Screwdrivers
Screwdrivers are one of the most commonly used tools in any household or workshop, essential for repairing or assembling anything that involves screws. Below, we break down the different types and parts of a screwdriver so you can identify the right one for your job.
Types Of Screwdrivers And Their Applications
There are several distinct screwdriver head types, each built for a specific screw profile. Using the wrong type – not just the wrong size – is a common cause of stripped screws.
- Slotted screwdrivers: Have a single flat blade that fits the straight slot on flathead screws.
- Phillips screwdrivers: Have a cross-shaped tip that fits the four-pointed slots of a Phillips screw head.
- Torx screwdrivers: Have a six-pointed star-shaped head, standard on deck screws, automotive panels, and electronics.
- Hex (Allen) screwdrivers: Have a hexagonal head used on furniture hardware, bicycles, and machinery set screws.
- Square (Robertson) screwdrivers: Have a square-tipped head common on Canadian-made deck and framing screws.
Parts Of A Screwdriver
Knowing the different parts of a screwdriver helps you understand why size and fit matter so much:
| Part | Description |
|---|---|
| Tip | The end of the screwdriver that fits into the screw head. |
| Blade | The long, straight shaft that connects the tip to the handle. |
| Handle | The gripping section used to apply torque and turn the tool. |
| Shaft | The section between blade and handle that transmits torque without twisting. |
Screwdriver Sizes
A screwdriver size is a measurement of tip width and blade length, expressed in millimeters for most head types. Phillips sizes are labeled #00 through #4 (smallest to largest); flathead sizes are given as a raw tip-width measurement; Torx and hex sizes use their own point-diameter scale. Choosing the correct size prevents stripped screws and damaged screwdriver tips.
What Are The Different Sizes Of Screwdrivers?
Screwdrivers are sized primarily by tip width, with Phillips and slotted heads spanning the smallest precision sizes (used on eyeglasses and electronics) up to heavy-duty construction sizes. Phillips runs from #00 (finest) to #4 (largest); flathead is sized directly by tip-width in millimeters rather than a numbered scale.
Manufacturers publish screwdriver size charts that map tip size to the corresponding screw gauge. Blade length also varies – from short precision drivers to long-handled construction drivers – but tip width is what determines fit, and a mismatched tip is the most common cause of a stripped screw head.
How To Choose The Right Screwdriver Bit
Before choosing a screwdriver bit, identify the screw head’s drive type (Phillips, slotted, Torx, hex, square, or Pozidriv), then match tip size so it fills the screw head entirely – not just closely.
A bit that’s too small will cam out and round the screw head; a bit that’s too large won’t seat and can crack the material around the screw. There are six common bit families: slotted, Phillips, Torx, hex keys, square (Robertson), and Pozidriv. Pozidriv looks similar to Phillips but has extra contact points for better grip and less cam-out – the two are not interchangeable despite the visual similarity.
Pozi Head Screwdriver Size Guide
Pozi screws are common in woodworking and cabinetry. Unlike standard Phillips screws, Pozidriv heads have four small extra ribs between the main cross – this extra contact area is what reduces cam-out under power-driver torque.
Pozidriv sizes are labeled PZ1, PZ2, and PZ3, roughly corresponding to Phillips #1, #2, and #3 in overall size – but a Phillips bit forced into a Pozidriv screw (or vice versa) will slip and chew up the head, so match the drive type first, then the size.
Screwdriver Size Chart
A screwdriver size chart lists tip width and blade length in millimeters for each head type and size. Different brands may vary slightly in exact tip dimensions, so treat the numbers below as a reliable starting reference and confirm fit by test-seating the bit in the screw head before driving.
Phillips Head Screwdriver Sizes Chart
Phillips head screws are the most common fastener drive type worldwide. Sizes run from #00 (finest) to #4 (largest), and each size is designed to match a specific range of screw gauges – the table below shows typical tip width alongside the corresponding screw sizes each Phillips driver is meant to fit.
| Phillips Size | Approx. Tip Width (mm)* | Matches Screw Gauge | Typical Use |
|---|---|---|---|
| #00 | 1.5-2.0 | #0 | Electronics, eyeglasses, watches |
| #0 | 2.0-2.5 | #0-#1 | Small appliances, hinges |
| #1 | 2.5-3.2 | #2-#4 | Small screws, light fixtures |
| #2 | 3.5-4.0 | #5-#9 | General purpose – most common size |
| #3 | 4.5-5.0 | #10-#16 | Large wood screws, machinery |
| #4 | 5.5-6.0 | #18-#24 | Heavy construction, large fasteners |
*Phillips tip width isn’t locked to one universal spec – it varies a little by manufacturer. The screw-gauge match is the more reliable way to confirm fit: try the bit in the screw head before driving.
Taparia Phillips Screwdrivers Size Chart
Taparia is a well-known screwdriver brand widely sold in South Asian and industrial-supply markets. Here’s how their Phillips sizing lines up with tip width:
| Taparia Phillips Screwdriver Size | Tip Width (mm) |
|---|---|
| 00 | 1.4 |
| 0 | 2.0 |
| 1 | 2.5 |
| 2 | 3.0 |
| 3 | 3.5 |
| 4 | 4.0 |
Flat Head (Slotted) Screwdriver Sizes Chart
Flat head – also called slotted – screwdrivers are sized by tip width rather than a numbered scale. The tip must match the slot in the screw head closely: too narrow and you’ll slip and round the slot; too wide and you’ll gouge the surrounding material. Precision drivers run roughly 1.0-2.5mm, general-purpose household drivers 3.0-5.5mm, and construction/automotive drivers up to 10mm – the most common household slotted size is 1/4″ (6mm).
| Blade Type | Tip Width (mm) | Blade Thickness (mm) | Blade Length | Typical Use |
|---|---|---|---|---|
| Micro / Precision | 0.8-3.0 | 0.2-0.5 | 40-60 mm | Electronics, eyeglasses |
| Stubby | 3.0-8.0 | 0.5-1.2 | 16-25 mm | Tight spaces, confined areas |
| Small Standard | 3.0-4.0 | 0.5-0.8 | 75-100 mm | Small screws, cabinetry |
| Medium Standard | 5.0-6.0 | 0.8-1.0 | 100-150 mm | General woodworking, furniture |
| Large Standard | 7.0-8.0 | 1.0-1.2 | 150-200 mm | Larger screws, construction |
| Heavy Duty / Long | 8.0-10.0 | 1.2-1.6 | 200-300 mm | Industrial, heavy construction |
Screwdriver Bit Sizes Chart
Screwdriver bits (also called driver bits) fit into drills, impact drivers, and screw guns. Standard bit shanks follow the ISO 1173 hex-drive standard (1/4″ / 6.35mm), while Torx point sizes follow a fixed point-to-point diameter scale – unlike Phillips, Torx sizing is consistent across manufacturers because it’s a patented, tightly toleranced geometry. Knowing the correct bit size prevents stripping and ensures maximum torque transfer. See the difference between drill bits and driver bits if you’re unsure which one you need.
| Bit Type | Size | Point Diameter (mm) | Shank Diameter | Common Use |
|---|---|---|---|---|
| Phillips | #0, #1, #2, #3 | 2.0-5.0 (varies by brand) | 6.35 mm (1/4″) | Most drywall, woodworking, general |
| Flat / Slotted | 3 mm – 8 mm | 3.0-8.0 | 6.35 mm (1/4″) | Legacy screws, cabinetry |
| Torx (Star) | T10, T15, T20, T25, T30 | 2.74 / 3.27 / 3.86 / 4.43 / 5.52 | 6.35 mm (1/4″) | Deck screws, automotive |
| Square (Robertson) | #1, #2, #3 | 2.84 / 3.36 / 4.83 (approx.) | 6.35 mm (1/4″) | Deck screws, Canadian standard |
| Hex (Allen) | 2-10 mm / 5/64″-3/8″ | 2.0-10.0 | 6.35 mm (1/4″) | Furniture, bicycle assembly |
📊 Torx point-to-point diameters are one of the few screwdriver measurements with a genuinely fixed industry spec – T10 = 2.74mm, T15 = 3.27mm, T20 = 3.86mm, T25 = 4.43mm, T30 = 5.52mm – which is why a T25 bit fits the same across every brand. Source: Wiha Tools, Torx Dimensional & Torque Specifications.
Do You Need A Different Screwdriver For Deck Screws?
Yes – most modern deck screws use Torx (T15-T25) or square-drive heads instead of Phillips, specifically because those drives resist cam-out under the higher torque of an impact driver. A Phillips bit will slip and strip a Torx-drive deck screw; check the screw box or head shape before buying bits.
Why Do Phillips Screwdrivers Cam Out More Than Torx?
Phillips heads were originally designed with a slight taper so the bit would “cam out” (pop free) at high torque, preventing tool or panel damage on assembly lines. Torx and square drives were designed later specifically to eliminate that cam-out, which is why they’ve become the standard for power-driven deck and construction screws.
Popular Screwdriver Sets
If you’re building a set that covers Phillips, flathead, and Torx in one case, these are solid options at different price points:
Best Screwdriver Set Pick
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- Best for: General household repairs and furniture assembly
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 Option 2 86-Piece Torx/Slotted/Phillips Set – $29.98
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 Option 3 Amartisan 43-Piece Magnetic Set – $19.99
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Choosing The Right Screwdriver
To determine the appropriate screwdriver size, refer to the size chart above and match the screwdriver tip to the screw head – not the screw’s overall length or gauge alone.
Matching The Screwdriver To The Screw
Matching drive type comes before matching size. There are several screw head types – Phillips, slotted, Torx, Pozidriv, hex, and square – and each requires its own correctly sized screwdriver to seat properly.
| Screw Type | Corresponding Screwdriver Type |
|---|---|
| Slotted Screw | Slotted Screwdriver |
| Phillips Head Screw | Phillips Head Screwdriver |
| Torx Screw | Torx Screwdriver |
| Pozidriv Screw | Pozidriv Screwdriver |
| Square (Robertson) Screw | Square Screwdriver |
Optimizing The Screwdriver For The Job
- Fully seat the tip in the screw head before applying torque, to prevent slippage.
- Choose a handle diameter that’s comfortable to grip for the length of the job.
- Match tip size to screw size exactly – a loose fit is the top cause of stripped heads.
- Use a magnetic tip (or a magnetizer) to keep small screws from falling during one-handed work.
Maintaining Your Screwdrivers
A worn or corroded tip changes the effective size of a screwdriver, which is why maintenance matters as much as picking the right size in the first place.
- Store dry: humidity corrodes tips and handles, rounding off the sharp edges that grip the screw head.
- Clean after use: wipe off debris with a cloth; use rubbing alcohol for stubborn grime.
- Oil moving parts: on ratcheting drivers, a drop of light oil keeps the mechanism smooth.
- Replace worn tips: a rounded or chipped Phillips tip will cam out even on a correctly sized screw.
Frequently Asked Questions On Screw Driver Size Chart
What Are The Sizes Of Screwdrivers?
Screwdrivers come in Phillips (#00-#4), slotted/flathead (measured directly in mm), Torx (T6-T50), hex/Allen, and square (Robertson) drive types. Tip width and length are measured in millimeters and vary slightly by brand. The four most common Phillips sizes for household use are #0, #1, #2, and #3.
How Do You Measure A Screwdriver?
Measure the tip width across its widest point with calipers, and the blade length from the handle to the tip. For Phillips and Torx, the size label (like #2 or T25) corresponds to a specific tip width – match the bit to the screw head by test-fit rather than by eye.
What Does #2 Phillips Mean?
#2 Phillips is the most common Phillips screwdriver size, sized to fit screw gauges roughly #5 through #9 – the range used by most general-purpose wood screws, cabinet hardware, and drywall screws. It’s the size most household screwdriver sets ship as the default bit.
How Do You Match A Screwdriver To A Screw?
Match the drive type first (Phillips, slotted, Torx, Pozidriv, hex, or square), then choose the size that fills the screw head entirely. A bit that’s too big or too small won’t seat properly and will strip the screw – use the charts above to confirm the size before driving.
What Size Screwdriver Is Standard For Household Use?
A #2 Phillips and a 1/4″ (6mm) flathead cover the majority of household repairs, furniture assembly, and appliance screws. Keep a #1 Phillips on hand as well for smaller hardware like hinges and light switch plates.
Are Torx Sizes The Same Across All Brands?
Yes – Torx point-to-point diameters are a standardized, patented geometry, so a T25 bit from any manufacturer fits any T25 screw. This is different from Phillips, where exact tip width can vary slightly by brand.
Conclusion
Choosing the right screwdriver size comes down to matching drive type first, then tip width, to the screw head in front of you. Phillips runs #00-#4, flathead is sized directly by tip width in millimeters, and Torx follows a fixed point-diameter scale that’s consistent across brands. Test-fit before driving, and use the screw driver size charts above to avoid stripped screws on your next project.
