It was big news in 2005 when Milwaukee Tool introduced the first cordless hand tool designed for the trades and powered by a lithium-ion battery. As other manufacturers introduced their own batteries, the lithium-ion power was a primary selling point.

With lithium-ion dominating the cordless market today, manufacturers are promoting the features and benefits of their battery brands, because all lithium-ion batteries are not the same.

Representatives of three leading tool makers serving electrical markets discuss the differences in these batteries below. 

Corey Hinkel, group product manager at Robert Bosch Tool Corp., Mt. Prospect, Ill., said the Core18V battery platform powers Bosch’s growing 18V product portfolio of cordless tools. Bosch continues to leverage the innovative design and heat management system in these batteries to power a wide range of cordless tools, from drill drivers like the 18V two-in-one impact driver and impact wrench, to the Profactor high-power lineup. 

Hinkel said key features of Bosch Core18V batteries are: 

• Advanced cell technology. Core18V batteries are equipped with one of the industry’s most advanced battery technologies. The batteries’ high-power cells produce higher currents for a longer time.
• Cutting-edge design. Bosch Core18V batteries include copper end plates, welded cell connectors and power rails that provide reduced resistance and greater efficiency, so tools can draw higher currents over a longer period of time. These batteries feature flexible printed circuit boards instead of multiple rigid boards and connectors for additional efficiency. 
• Heat management. Bosch Core18V batteries are equipped with CoolPack 2.0 technology that delivers longer life for the batteries with better heat management to protect the cells from damage. A cooler running battery operates more efficiently for a longer time. 
• Quick charging. The Bosch 18V turbo charger with power boost mode can charge a Bosch Core18V 4-Ah battery to 50% in 9 minutes. It can also charge a Core18V 8-Ah battery to 50% in 15 minutes and to a full charge in 51 minutes, helping workers get back to work faster.

“Bosch has designed cordless products for electrical work that include the following categories: impact drills/drivers for various applications, including driving screws and fastening applications; oscillating and reciprocating saws for cutting through walls to install fixtures and wiring; rotary hammers for difficult driving applications; and laser leveling tools to mark locations of switches and boxes on walls,” Hinkel said.

He said lithium-ion battery technology has enabled Bosch to expand its cordless tool line.

Bosch’s Profactor lineup of cordless high-power tools is engineered to tackle the tough jobs that typically require the power of corded tools.

“The hammer category is a leading example in which Bosch cordless technology delivers in the performance typically expected from corded hammers, and the newest rotary hammer outperforms its Bosch corded equivalent,” Hinkel said.

David Veprek, vice president of global product management at DeWalt, Towson, Md., said innovations in cordless battery cells, electronics and brushless motors are making it possible for entire job sites to go cordless. 

DeWalt PowerStack 20V MAX compact battery
www.dewalt.com

“This helps to reduce the need for temporary power setups, gas generators, air hoses and cords, which can be costly and hazardous on a job site,” he said. “Tools including nailers, rotary hammers, pipe threaders and press tools have all gone cordless.”

DeWalt is the world’s first major power tool brand to use pouch cell batteries designed for the construction industry, which has opened up the next frontier of performance and productivity, and changed how the pros work. 

“Pouch cells utilize the space that’s otherwise wasted between cylindrical cells, resulting in more stored energy through a more efficient use of the housing,” Veprek said. “This breakthrough technology uses a stack of five pouch cell batteries, which offers less internal impedance, a longer lifespan and a superior use of space that’s capable of powering a demanding, cordless job site. Through this revolutionary design, the LT PowerStack 20V MAX compact battery delivers the lightest and most powerful compact battery from DeWalt. The maximum initial battery voltage, measured without a workload, is 20V. Nominal voltage is 18V.” 

Veprek said the battery has 50% more power compared to the DCB203 (not in application), enabling broad application capabilities and fast performance of cordless tools, and is 25% more compact and 15% lighter than the DCB203. The battery is designed to make the tool more maneuverable and help reduce fatigue when working in tight areas, while having twice the lifespan in charge cycles compared to the DCB203.

“Another huge benefit to users of DeWalt cordless tools is that PowerStack batteries are compatible with the full suite of DeWalt 20V MAX tools and chargers,” he said, “so there’s no need to buy new tools in order to incorporate this next-generation technology.”

The DeWalt cordless tools electricians widely use include the compact 12V bandsaw, 20V cable stripper and 20V cable stapler, Veprek said. 

The cordless 12V ¾-inch brushless bandsaw weighs only 6.54 pounds, has an integrated guard and cuts through small metal diameters, with additional room to cut 1 ⁵/₈ inches comfortably. 

The 20V cable stapler is built for residential wiring applications, primarily fastening Romex brand wires and cables. This stapler has a proprietary cable guide to help drive staples over cable. 

The availability of lithium-ion power enabled DeWalt to add a cordless pipe threader for black iron rigid pipe threader to its product lineup. Designed to thread ½- to 2-inch conduit, it has an oil-resistant, glass-filled nylon battery to protect it from cutting oils used to complete threads and is housed in a latched and sealed battery box. Its E-Clutch system senses the motion of the tool and shuts down if necessary in bind-up situations.

Maximum initial battery voltage (measured without a workload) is 20V. Nominal voltage is 18V.

Zafir Farooque, senior product manager at Milwaukee Tool, Brookfield, Wis., said not all lithium-ion batteries are created equal.

“Our Redlithium batteries deliver greater power, last longer and perform smarter than other batteries on the market,” he said. “All of our batteries have world-class cell technology to deliver the highest performing packs on the job site.

“Our batteries feature Redlink Intelligence, a robust electronics package that monitors individual cell health, temperature and protects from overloading. With best-in-class construction, our batteries are designed and built to withstand drops, vibration and manage ingress of water, dust and debris.”

Ever since Milwaukee Tool first introduced lithium-ion technology for power tools, the capabilities of cordless technology have been pushed to new limits, providing new solutions that challenge existing perceptions of what can be powered by cordless technology, Farooque said.

Milwaukee Redlithium battery family
www.milwaukeetool.com

“This same philosophy went into our M18 Redlithium High Output batteries, which deliver higher power output and run cooler,” Farooque said. “High-demand tools can run harder for longer, allowing new cordless solutions to outperform corded, pneumatic and gas-powered tools.” 

Farooque said an increasing number of cordless tools with the ability to perform tougher or higher capacity applications are on job sites today.

“For example, our MX Fuel handheld drill features a patented clutch and auto-stop technology for maximum control and prevents over-rotation in case the tool gets bound up. The MX Fuel Redlithium battery pack powers through concrete and block almost anywhere, without the hassle of extension cords or tripping breakers.”

 Farooque said while handheld power tools have received considerable benefits from cordless technology, the same could not be said about light equipment. In 2020, Milwaukee disrupted the space with its battery­-powered MX Fuel equipment system. MX Fuel can provide instant power with no gas headaches, does not require regular maintenance and produces less noise and zero emissions indoors and outdoors. 

“For example, our M18 Fuel pipe threader was the industry’s first cordless pipe threader to outperform corded threaders, maximizing productivity without compromising the quality of the thread. Our M18 Redlithium High Output batteries allow the threader to deliver unmatched run-time in all applications with the power to thread up to 2-inch rigid metal conduit.”

“We are delivering a continuous flow of advanced, trade-specific solutions,” Farooque said. “Some of these categories include drills, impact wrenches, crimpers, bandsaws, knockout tools and personal lighting. 

“Milwaukee is unwilling to slow down. We are dedicated to solving user challenges and improving their day-to-day experience through game-changing tools and equipment that offer unmatched levels of performance, productivity and durability. We have invested in world class battery labs to ensure the cells in our Redlithium batteries exceed user expectations,” he said. 

Milwaukee partnered with leaders in the battery cell industry to deliver the best solutions for its battery lineup. The focus is on using the best-in-class lithium-ion cells and designing batteries to protect the cells and withstand the harsh conditions of the job site. Milwaukee also uses advanced electronics that maximize a tool’s performance without sacrificing compatibility. 

“Our dedication to improving workplace productivity and safety has driven us to develop over 250 solutions in our M18 battery system,” Farooque said, “allowing users to perform an entire day’s work on one battery system. 

“Our M12 tools are the most powerful subcompact cordless tools in their class, with over 125 compatible tools. Safer and more productive than gas or corded equipment, the MX Fuel equipment system is compatible with all MX Fuel Redlithium battery packs, giving users the hardest working and most reliable power equipment,” he said.

Header image: Bosch Core18V lithium-ion battery www.boschtools.com