I wanted to tackle that issue by using "
square washers" instead
[I do know it's probably not worth the trouble to modify everything in order to integrate a different shape into the design, but it'll solve that problem completely].
Note: I'm not vouching for the website that I've included as an example.I didn't know these existed, but it seems an option as well! In general the cool thing about these products is that the price / weight of stainless steel is so so cheap. I don't think they would stay on a screw as nicely as round washers, but it would be doable. When I'll find time to sit at the CAD again, I might give it a shot, though I don't have such washers here to try / experiment with.
I don't really see another way to hold a round object in place other than friction to be honest.
It would be a significant amount of additional work for
very marginal gains, but you could cut a small wedge out of each washer and modify your jig design so there is a small piece which sticks out in to the wedge cut-out to hold the washer in place. Almost certainly not worth the time, though. Your other option would be to buy square or other non-round washers, but again, you would obviously need to redesign your whole jig.
It sounds like your set up works fine with tape though. If you really mess up a washer by trying to punch it twice and being out of alignment, then you can just make a new one - it's not like you've messed up the entire back up as you might have done with a single steel plate.
I agree; the gain is small and it's really easy to put a piece of tape there. Or not, but then maybe only stamp a letter once. As you said, it's great that each word has its own washer with costs just a few pennies, so even if a letter comes crooked due to omitting tape, just take another washer. I have to say; I never had such a good looking steel backup..
I know, you can create a jig for a steel plate, but if you still mess up, you will need a new $20 plate.