Symptoms
- Tip slips or cams out of the screw head easily
- Tip looks rounded, chipped, or mushroomed at the end
- Driving screws now strips their heads more often
- Tip doesn't seat fully into the screw recess
Likely causes
- CommonNormal wear from repeated useMetal tips gradually round off, especially on cheaper drivers.
- CommonUsing the wrong size or type on a screwForcing a mismatched tip wears both the tip and the screw head.
- PossibleUsing a screwdriver as a pry bar or chiselOff-label use bends or chips the tip geometry.
- Less commonLow-quality or soft steel driverInexpensive tools use softer metal that deforms faster.
What to do
- Compare the tip to a new driver of the same size and type to confirm it's actually worn versus just dirty.
- For a flathead tip, a light touch-up on a bench grinder or file can restore a flat, square edge.
- For Phillips, Torx, or square-drive tips, reshaping isn't practical; plan to replace the bit or driver.
- If using an interchangeable bit driver, swap in a fresh bit rather than replacing the whole handle.
- Match driver size precisely to the screw head going forward to slow future wear.
- Keep a small set of quality bits on hand since cheap bit sets wear out fastest.
- Store bits and drivers separated from other metal tools to avoid tip damage in a drawer.
Tools and parts
- Bench grinder or file (for flathead)
- Replacement bits or driver
Replacement screwdriver bitsSearch: “screwdriver bit set replacement”
When to call a pro
Not typically a job for a professional; hardware stores can advise on matching bit types for specialty fasteners.
Safety
Generally low risk
Generally low risk for a careful person. Stop if anything looks different from what this guide describes.