How DeWalt is making job sites more efficient

Last year, DeWalt, a job site equipment manufacturer based in Towson, Maryland, launched the DeWalt PowerStack 20V Max compact battery. The company, owned by Stanley Black and Decker, says the battery will increase efficiency, performance and productivity on construction and demolition job sites.

“Power tools typically use cylindrical batteries that were not designed for high power applications,” says Sean Fitzgibbons, director of product development for Black and Decker. “With PowerStack, DeWalt was able to essentially develop a specification that new technology created for the uniquely high-power demands of power tool applications.”

Fitzgibbons says that although cylindrical batteries were not made for high-power applications, the economies of scale that were made possible by their use in electric vehicles made them affordable for other applications. However, when a higher current is run through those types of cells, they tend to heat up. Once they reach a certain temperature, they must shut down the battery. Another example of the cylindrical battery’s shortcomings is if more power is drawn through the device than those cells can provide, they shut down.

The PowerStack is a compact battery that uses pouch cell batteries, which are small rectangular batteries that have been stacked on each other.  The main difference between the pouch cell batteries and cylindrical batteries typically used in other power sources is that they have large surface area connective tabs that are built into the cell. Those tabs are then laser welded together with the neighboring power cell, which creates a reliable, electrically efficient connection that delivers more power.

Compared to batteries from cylindrical cell batteries, the company says the PowerStack has 50 percent more power and has twice the life span. It is also 15 percent lighter and 25 percent more compact than other batteries. Due to the design of the batteries, they also run 30 percent cooler, which means less downtime.

“One of the things … that we try to do at DeWalt with product development is helping our end users become more productive and there are multiple ways to do that,” Fitzgibbons says. “This battery has a longer lifecycle, increased power and is lighter weight. This increases how quickly jobs can get done, reduces fatigue from holding power tools all day and generally means a better return on investment for the contractor.”

The company says the battery includes several features to optimize functionality. This includes a battery pack with a LED fuel gauge that displays the battery’s state of charge, helping the end user avoid unplanned work stoppages. The batteries are designed with a durable, non-marring rubber over mold that provides impact resistance while helping to protect finished surfaces. 

The battery is ideal for cutting, drilling and fastening applications, precision and finishing tasks and when working in tight spaces. The battery is compatible with all Dewalt tools and chargers in the 20V max system.

While the company recently introduced the battery packs last December, it already has plans for expansion. Fitzgibbons says DeWalt will be introducing high-capacity versions of the PowerStack.

“We are going to be taking that PowerStack fundamental technology and bringing it into the market in a different capacity this year,” Fitzgibbons says. “It will expand the range of what you can do with PowerStack now that we'll have a compact option and high-capacity option.”