An I-bar clasp is a popular retainer for distal-extension removable partial dentures. However, there have been almost no evidence-based criteria on the mechanically preferable shape. The present study aimed to investigate the variations of dimension in I-bar clasps used in patients, and to clarify the effect of the variations on stiffness and stress of I-bar clasps by finite element analysis. Dimensions (thickness, width, taper, radius of curvature, length, relation to oral structures) of 23 I-bar clasps were measured. A three-dimensional finite element model was made for each measured I-bar clasp with vertical and horizontal straight sections connected with a curved section. A concentrated load of 5 N was applied at the lowest point of the tip that contacted the abutment in the buccal direction. Maximal equivalent stress and stiffness of each clasp were evaluated. The measured dimension, stiffness, and maximum stress showed wide variations. Mean stiffness was far from the proper one, and mean stress was near the proportional limit of Co-Cr alloy. Considering the stiffness and stresses in this study, only six clasps out of 23 were appropriate. These results suggest that evidence-based criteria of preferable shape of I-bar clasps should be determined.