I’ve been following and reporting on the tool industry for more than 12 years now, and there have been quite a few game-changing cordless power tool innovations in that time.
It seems that every time cordless tech and developments plateau, a tool brand will take things to a new level, kicking off a new round of innovations and fierce competition.
Cordless developments seem to be plateauing once more, and I can’t shake the feeling that we’re approaching another such inflection point. If so, what will come next?
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Let’s take a look at some of the big upgrades that ToolGuyd has been reporting through.
From NiCad to Li-ion
A little more than 10 years ago, brands started converting over from NiCad battery tech to Lithium-ion, at least for their flagship products.
Li-ion batteries held many advantages, although battery cell tech wasn’t very close to where it is today. Early on, for example, there were complaints about Li-ion batteries performing very poorly in colder temperatures.
Many brands created new cordless power tool systems and battery form factors based on Li-ion tech, leaving NiCad and other battery technologies behind, while others simply upgraded their battery packs.
Lithium-ion batteries brought about a new era of cordless power tool advancements, ultimately leading to the idea of a “cordless jobsite.”
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Bigger Batteries and Longer Runtimes
Lower battery cell capacities and power-hungry motors led to meager runtime specs compared to today’s standards. There was a hard limit on power tool performance, which limited the types of tools brands could offer.
For instance, 6-1/2″ wasn’t a compact circular saw size a few years ago, it was the only or largest option for many brands.
Higher battery cell capacities led to dramatically longer runtimes, which meant fewer interruptions and trips to the charger.
It seemed that each major step up in battery capacity was a significant achievement.
At the same time, many tool brands were continuing to expand their lineup with new product types and upgrades to earlier models.
Brushless Motor Tech
Brushless motors have changed everything yet again, and I would say that this has been as important a development as the advancement of Li-ion batteries.
Brushless motors are more efficient that brushed motors, which means more power, extended runtime, or often a combination of both.
We now have cordless table saws, 12″ miter saws, and so much more.
Earlier cordless grinders were simply described as cut-off tools. Why? I was told that it’s because they didn’t deliver enough power or runtime to be advertised for cordless grinding applications. Now, there are not only cordless angle grinders but larger ones.
Higher Voltage Cordless Systems
Cordless tool brands diverged when it came to next-generation cordless tools.
Some brands, such as Makita, doubled up on 18V batteries to deliver higher voltage tools, and other brands, such as Dewalt and Metabo HPT, opted for higher voltage battery packs that were also backwards compatible with their lower voltage systems.
Higher voltage cordless power tool systems seemed to all but disappear, only to reemerge with next-level brushless motors, power, and capabilities.
Quite a few brands also created higher voltage platforms to offer better performing cordless outdoor power tools, paving the way for alternatives to electric and gasoline engine tools. Developments and innovations in the cordless OPE and landscaping industry have largely paralleled those in the construction, trades, woodworking, hobbyist, and DIYer tool industries.
Higher Li-ion Output Batteries
We also now have even higher capacity batteries.
There are actually two parts to this. First, some brands, starting with Milwaukee, added an extra row of cells to their highest performing batteries. Milwaukee kicked things off with “HD” batteries built with 15 cells instead of 5 or 10, and other brands – Bosch and Dewalt – have done the same.
So, we now have batteries with more batteries. Both on top of that and separate from it, we also now have batteries built with larger form factor Li-ion cells.
Earlier – and current – battery tech involves 18650-sized Li-ion cells, and newer higher performing batteries feature 21700-sized cells. The 5-digit classification refers to battery cell standards and nominal dimensions, with 21700 cells being physically larger than 18650 sized cells.
When you have a physically larger battery cell, you can have comparable charge capacity with lower charge density, which results in cooler-running batteries that can deliver greater current output. Or, you can reach new levels of battery charge capacity. There’s enough headroom where we now have higher capacity battery packs that can deliver more power and longer runtime compared to older Li-ion battery pack tech.
What this all means is that modern battery tech and brushless motor tech can combine to deliver new levels of power and performance.
Compact and More Affordable Brushless Motor Tech
It used to be that only the most premium and highest performing cordless power tools featured brushless motors. Brushless motors were a feature reserved for tool brands’ flagship tools.
Now, we have “subcompact” and even value-priced brushless options.
Brushless motor tech has become so commonplace these days that some brands don’t even emphasize it anymore.
More Controls and User Settings
Brushless motors have also unlocked new features and capabilities that are tied into their more sophisticated controls.
A brushless vacuum, for example, might have multiple power and suction settings.
Or, you might have a brushless impact driver with multiple speed and torque settings.
Today, you can find brushless tools with multiple power settings, electronic clutches, and special speed modes, with none of this really being possible with brushed motor tech, at least not as easily or feasibly.
What Comes Next?
Cordless power tool has come a long way, and with some of the advancements discussed above changing things in very big ways.
We have not quite reached a new power and performance ceiling, but I cannot help but find myself wondering about what comes next.
I hoped that detailing the major milestones would help me see where things could be going, but all I can see is the obvious. Some of the Li-ion advancements came as a surprise, such as the introduction of 3-row/15-cell batteries. What new surprises might there be in the near future?
Milwaukee Tool launched their MX FUEL cordless equipment system nearly 2 years ago, and there hasn’t been much expansion since then. Dewalt has a new 15Ah FlexVolt battery, and it looks like it be the spearhead of something big for the brand. Even Makita has a new high cell-count battery as part of their XGT system.
Dewalt has also been blurring the line between FlexVolt and 20V Max, such as with their new cordless air compressor. Could this be tied to the brand potentially taking FlexVolt into a new and even higher powered direction?
I feel that fierce competition at the next level of higher performing cordless power tools and tech is bound to happen, where brands strive to offer next greatest “I can’t believe that’s battery powered” tools and equipment. This would be an easy prediction to make, that another ceiling will be broken through, unlocking a new tier of cordless functionality and capabilities.
But, there are always “quality of life” types of improvements that follow in the wake of every major advancement. For example, each new generation of cordless drill is made smaller and smaller, and the same has been true for impact drivers and wrenches. Impact tools have also benefited from new fastener tightening and loosening modes that brushless motors made possible.
We also have tools with anti-kickback tech, but this hasn’t seen as wide adoption as other modern features.
What do you think will come next? What do you want to see come next to cordless power tools – are there any features or capabilities that will improve your work or user experiences in some way?
Norman Huizenga
One thing that was interesting that didn’t really take off, is interchangeable tool heads (black and Decker matrix)… Or maybe it sold it’s limit. It seemed to stop evolving. On the other hand, Bosch and Milwaukee both have interchangeable head screw guns, love mine. So maybe that’s a pro vs home owner type difference.
Another advancement was the yard tool options.
If anything I think more speclized and variety of tools will keep on coming out.
MrS85
B&D Matrix and Craftsman Bolt-On (interchangeable attachments) were just underpowered in my experience. The two best heads were the oscillating tool and the jigsaw, but they were just awkward to use while holding onto a drill. Then on the other hand, the motor was two weak to really power the drill or driver, and certainly not the mini-circular or reciprocating attachments. I really agree it was a good concept, but just cheaply and poorly implemented with the brand(s) that used it.
KenZ
I would like to see that applied to pin nailers. 18ga is what I have but every once in a wile I would like 16.
Russell
The concept of having multiple tools on a drill was popular from the late 40s to the 60s because even cheap power tools were expensive compared to today’s cheap power tools. Craftsman, Millers Falls, B&D, and others had drills with attachments that either fit in the chuck itself or by taking the chuck off and putting it on the spindle. I think Craftsman in the 50s had circular saw attachments too, such as a chainsaw, table saw and a radial arm saw.
Flotsam
i agree i remember looking at old archives of tools (archive.org. The drill was the first tool that most people would buy. I admit i’ve never tried it but trying to run a small circular saw off a drill looks very very sketchy.
In modern iterations, like Ridgid jobmax its much better thought out. I have a lot of jobmax stuff mostly used or discount.
Alan
Ridgid tried that with their Jobmax system. The tools were jack of all trades and master of none. The motor base was light weight and some of the heads were overweight making a very unbalanced tool to hold. Clever idea but I was not happy with it
MM
Battery tech will continue to advance on its own and power tool companies will constantly be updating their battery packs based on what is available. And that, in my opinion, is where the most significant improvements will all stem from. It’s possible for a brushless motor the size of a soda can to crank out ten horsepower. Or more; the only reason those aren’t in power tools already is that there’s no way our current battery tech, with reasonable size and weight constraints, can deliver reasonable runtime. Better battery cell tech helps the tools in two ways. Not only is the energy density higher which provides for longer run times, but it’s also possible to increase voltage. So instead of the 40V and 60V packs of today we might have 120V or 150V packs in the future. Higher voltage means lower current for the same power, so that reduces the size and weight of contacts, cables, the transistors in the electronic speed control, etc. With higher voltage a motor can be physically smaller and deliver the same power. All this will make for more compact tools. I think at some point that will introduce a new battery format which will fit inside handles sort of like the old Makita Ni-cad sticks or M12, but much smaller so it doesn’t require a fat grip.
In the near future I think we’ll see more high power tools since all the major brands seem to be coming out with new higher power batteries recently. The battle for cordless lawn mowers is starting to heat up and it won’t be too long, IMHO, before we see ones that compete with gas models on power though we’re not there yet on the standard 18V-ish platforms. That will also drive new high power batteries. The new products will be those currently powered with small IC engines, or relegated to corded power. I’m thinking cordless table saws, larger compressors, larger rotary hammers/breakers, larger cutoff saws, grinders, pipe threader, AC inverter capable of running large loads, vacs.
I also think we will see improvement in accessories. Years ago the saw blades, etc, which came with a new saw were junk, as were the same brand’s line of optional blades. You wanted a good blade you went 3rd party. But I’ve noticed many newer tools are shipping with honestly good blades. Not Forrestt Woodwoorker II good, but remarkably good for being a “freebie” with the tool. I think that the companies realized that shipping their tools with good blades improve the user experience, and therefore the brand’s reputation, a great deal. There are engineering tricks as well: thinner kerf blades require less power to cut making them ideal for use on cordless tools with limited battery capacity. This lets them quote longer run times or more cuts per charge. I think we’ll see more of this kind of thing since it seems that all the big makers are putting more efforts into their drill bits, saw blades, hex bits, grinding wheels, etc. Even though 95% of my grinding discs come from welding shop brands like Norton, I was surprised to find that Makita of all brands is making some damn good .035 x 5″ cutoff discs, which not only cut great but are long-lasting as well.
Now that fancier electronics and bluetooth, etc, are finding their way into cordless tools I hope nobody starts getting any ideas like we’ve seen already with other technology. For example, how Apple started throttling the speed of older Iphones in an attempt to force people to buy the new model even though the old ones were working fine…well, they WERE working fine until Apple’s mandatory update was installed. Or perhaps how Kuerig coffee machines used RFID tags to refuse to function with 3rd party coffee pods. Of course this was all done in the name of *safety*, because lord knows what might happen if you bought coffee from someone other than Kuerig. Or even worse, juicero. I can see it now: you don’t actually own the that new drill, you’re just leasing it as long as you’re making payments. If you stop paying it stops working. After it’s drilled 5000 holes it shuts off and the “maintenance required” messages start getting sent to your phone, meanwhile it’s ordered itself a prepaid return shipping label & box, and billed you for this–all part of the contract. Speaking of which, the drill records data of how, when, and where it was used, and by whom. It periodically takes pictures of the work area in front of it and sends them back to HQ for “product performance monitoring”. Oh, and it’s RFID locked to bits and blades, so the Skilwaukee saw won’t turn on with a DeBosch blade installed–for safety, of course. And that new Flexbi drill? They advertise it will use any brand’s bits…but if equipped with Flexi bits it unlocks “turbo hole mode” for 25% better drilling performance….
IronWood
God I hope the software as service and in-app purchase models don’t creep into tools. No wifi bluetooth smart home stuff in the shop please! I don’t want to have to log into my drill press and skilsaw, thank you very much. I feel myself turning into my grandfather day by day…
Jared
Especially with the behaviour brushless motors have unlocked, like Stuart mentioned, more “smart tech” has to be coming for tools. Maybe I’m over optimistic, but I doubt the innovation will be intentionally obtrusive.
I imagine custom profiles – maybe adjustable speed, torque and clutch settings for fastening tools, or tuneable triggers. Nothing you must mess with regularly, but something you can setup with a new tool or adjust from a base setting.
What about a jigsaw that could track a drawn line as long as you kept it inside a window?
A flashlight where you can set any brightness levels to correspond to any custom click pattern you want (and you luddites can just make it be “on” and “off” 😄).
Maybe a torque wrench with real torque settings?
What about an impact driver that can scan a box of deck screws and adjust its behaviour to suit
Chainsaw with sawstop tech?
Let’s try it all and Stuart can advise whether it sucks or is worth buying.
MM
Putting sawstop tech in a chainsaw would be huge.
And honestly with an electric saw it would be even easier to implement. The electronics can stop the chain by using the motor as an electric brake. It wouldn’t need a physical object to stop the chain. It could also detect chain breakages and likewise stop the sprocket to reduce the chance of injury from a chain whipping around. We just need battery tech to advance a bit until it makes sense for full-size saws.
I know an older gentleman who works as an arborist and still climbs trees himself. He loves the cordless saws for climbing. There’s no hassle of constantly having to start and stop the saw and he found they had plenty of power for typical pruning tasks, say 5″ limbs and under. However he reported that they are essentially useless for larger work when he has to remove trees, many of which can be quite large. Anything larger than 5-6″ or so and the cordless saws, according to him, become radically underpowered. And then there is the issue of runtime and charging speed. He can bring a couple fresh batteries for his climbing saw when he goes to work in the morning and make it through a day of pruning no problem. But cutting up larger limbs for removal drains batteries on the bigger saws much faster than they can be charged, while it takes 30 seconds to refill the tank on a gas saw.
Paul
Disagree strongly. It’s ridiculous to try to cram a few buttons and lights or a screen on a power tool. Think about a torque wrench. It would be nice to set the torque limit and/or switch to fastener driving mode. We almost have that now but one button and a couple lights or a settings ring is limited compared to a huge potential menu on a phone running on Bluetooth without a server. This can be very convenient if it works well, or very bad if it doesn’t.
I used to carry shelves with tech manuals on the truck too for industrial equipment. VFD manuals are now over 500 pages each, More and more drives came out with a QR code on the sticker that opens the manual. Even better Schneider puts a QR code on the screen that opens the manual to the exact page for a fault code. Now my “shelves” carry more tools.
In years past we had to buy a $4000 HART tool plus a monthly subscription costing hundreds a year to program a lot of instruments. It is a decent but highly overpriced solution. Bluetooth with phones bypasses this as an almost free solution.
I also have s cheap horoscope. I constantly use the camera both for seeing hard to see things and looking around corners. IR cameras that plug into phones are cheap, Our company schedule and time sheets are on phones. Heck I can even check on the home network when the kids are having problems while on the road.
I can’t imagine the ost increase and reliability issues adding buttons and screens to power tools. Never mind the huge cost reduction that cell phones gave to “camera” tools like horoscopes and IR. Done well it’s a huge benefit. Done badly…you get a crippled tool.
IronWood
Good points. I think the examples you give are a bit different than what I’m afraid of. QR codes for support and digital manuals, or multimeters, scopes, and imagers using a phone or other device for data logging or remote viewing are excellent examples of adding connectivity to tools. I get that and I use them myself.
My main concern is the idea of going to tool licenses or subscriptions, like Microsoft or Adobe, or in one of Stuart’s other articles about Home Depot’s shoplifting tech dream. I understand that for some proprietary tools, such as diagnostic or programming units this might be unavoidable. That’s not really what I’m talking about. If I get to a work site and then have to make sure my power tools can get their security updates and connect to the license server I’ll just hang it up.
I also have a problem with “normal” type tools, as opposed to those fundamentally built on high-tech like scopes and meters, getting too complicated. I don’t want to have to pay for a dozen features I rarely or never use just to get pro level quality in the future. I don’t want to be unable to use a tool because my phone crapped out or the software is unhappy. I expect FLIR to make their newest IR cameras sophisticated, connected, and fancy; DeWalt doesn’t need to do the same with a hammer drill or jigsaw.
MM
The last thing I would want out of a torque wrench is to require my phone to use it. If I need the torque wrench my hands are probably very dirty….and someone wants me to pick up a smartphone and operate it with greasy fingers? Or am I supposed to go wash up every time I need to change a setting on the wrench?
Personally I’ve never found an old-school micrometer torque wrench to be inadequate. I’ve seen the electronic ones from Snap-On, they seem to work with just an pair of up/down buttons. That makes a lot more sense to use with dirty mechanic’s hands than a touchscreen phone.
William Adams
I believe that is covered under:
https://hackaday.com/2021/08/02/home-depot-is-selling-power-tools-that-require-activation-in-store/
Dave
This comment is like the book 1984. It was never meant to be a how-to guide, you guys…
fred
Perhaps not in my lifetime – but I think we can expect another paradigm shift in battery technology. While the battery design goals for the EV market may be different from the batteries needed for tools – the amount of work being done is bound to have some spin off. So thinking that we are wedded to LiIon chemistry for decades to come – may be limiting. What if there are breakthroughs on silver-zinc – or some other chemistry that we are not even contemplating? If we had cell couples that significantly increase energy density over LiIon – we might make further inroads into replacing pneumatic and corded power tools used for demanding tasks.
Battery cooling may be another thing that gets worked on more assiduously as we reach the limits of LiIon.
Jim Felt
fred. Maybe Elon Musk will buy a tool manufacturer on a whim and name the highest powered tool versions “plaid”?
Serendipity
Considering Tesla can’t even understand how to open a glove box I don’t trust them at all with power tools.
Jared
Maybe we’ll have a M12 stick welder eventually.
Robert Feliciano
Laser cutters.
Okay, maybe not next, but that’s where we are headed.
Forget saw blades, laser beam cutters: think of the tiny kerf.
Mirror to help with measurements: routers that cut to a specified depth and then shut off power.
A gimbal and mirror that bounces the light around controlling width as well.
No more saw dust.
Lasers!
MM
I have a small laser cutter in my shop. There are three huge problems that need to be overcome here.
First is that lasers project a fairly large beam from the tube itself, then use lenses to focus it where it cuts. That gives the cutting beam an “hourglass” or “double cone” sort of shape. Thus it cuts thin materials well, but as the material gets thicker the kerf gets bigger due to this angle.
Second is safetey. It only takes a fraction of a second for a laser to blind you, thus any one with significnt power operates inside an interlocked box so the beam can’t get out. Without this a beam could easily bounce off something shiny, even for just a moment, and seriously injure a worker or start a fire.
Third is physics. Any sort of powerful laser requires a massively heavy foundation for the laser resonator. That’s not something you can just carry around to a jobsite.
Oh and they do generate no sawdust, but they sure do generate smoke and noxious vapors that need removal. My tiny little machine, 18″ x 40″ cutting area, takes a 3HP exhaust blower.
IronWood
Interesting discussion. Obviously battery and motor tech will continue to develop. Realistically I think the “core tools” in each brand are about as good as they need to be; there will be incremental improvements, but 18V (or 20V or 24V) drills, saws, impacts, etc. don’t really need to get much better.
I see the next competitive arenas as the big and small ends of the spectrum. Cordless tools that go head to head with more gas power equipment and with compact air tools should be the goal. As an example, only Milwaukee has true air tool form factor die grinders, and they’re still too big for me. Smaller more capable batteries for super compact die grinders, ratchets, drills, polishers, belt grinders, air-style recip saws would be awesome. On the big end better lawn mowers, chainsaws, demo saws, breaking hammers and the like must be coming.
I’d also like to see a really good cordless belt sander. Preferably DeWalt. Please??
MM
Competing with air power would be huge. And I think we’re on the cusp of it. I have a couple of the M12 die grinders, they’re a bit bigger than my old pneumatic ones. They’re roughly the same power as standard pneumatic models but they are in no way as powerful as the nicer pneumatic ones, even compact size. I have a 3M plastic bodied pneumatic die grinder that stomps all over the M12 and is in fact about as powerful as the rather large DW 20V max die grinder. I’ll be really happy when the compact tools reach that kind of power level.
Same with the larger grinders and sanders….they’re nice, but they’re no Dotco. I really would like a 7″ flathead cordless grinder, right now I think the only one making those is Metabo.
Matt
I’d love to see more mechanical tools – like a motorized torque wrench! Digital control plus more precise motors could make that work.
Plain grainy
Solar: Tool manufacturers will probably be offering portable solar panels( solar generators). Thus giving contractors the ability to charge tool batterys, and power job site off grid. Solar generators can be charged off of the company’s own solar panels, then taken to job site.for battery charging, powering tools there.
Electric vehicles: Using electric vehicles to charge batteries, power job site.
All about the charge: I think the biggest changes won’t be from new battery or tool technology, but rather how we will charge these batteries & power job sites.
Chuck
The F150 Lightning is going to be available with a “generator” that can power a light house load, so it can probably cover some jobsite functions.
Most EV manufacturers shy away from allowing people to use the car’s battery for anything other than driving, so hopefully this forces others to allow the battery to be used.
Branden H
“Sufficiently high enough technology is indistinguishable from magic”. Breakthroughs will continue to happen that will make motors both smaller and more powerful at the same time. Battery chemistry will get better as well. Each of the improvements you mentioned seem small on their own but synergistically they make a huge difference in how the tools perform. I’m 32 and have worked in the trades since I was a teenager and the difference in cordless tool performance and size/weight is insane. Most high end 12v impacts perform better than anyone thought possible 15 or 20 years ago.
JoeM
The direct quote from Arthur C. Clarke is “Technology, Sufficiently Advanced, is Indistinguishable from Magic.”
No comment or criticism. Just, more people will recognize the quote in its original form. Carry on Branden H.
Branden H
Thank you! I’m ready for my job site lightsaber whenever. Would the Milwaukee be red by default?
JoeM
As far as I can tell, the place Power Tools go “next” is Mobile Integration.
We’ve seen experiments with BlueTooth tracking and tweaking technologies, I think it will extend to Company-Owned Check-In, and Check-Out Tracking of both tools, and a bio-tracker that will inform the foreman about the state of everyone on site.
Think of it as the Construction and Trades equivalent of a FitBit. Just a strapped on watch-type-object that multi-functions on both ends of the system. It identifies medical and environmental needs on the user end, and both activity time, as well as health status with location on the tracking end.
Shift 1 ends at 3PM, the tracker beeps the shift change, but also has been monitoring health stats the whole time. So, if Bob is working on the roof somewhere, and has either a heat stroke, or a heart attack, his exact location is known, his tools he registered all start sending out the alert signal to the main base station, and the medic knows to go directly to Bob’s location with water and some shade, probably grabbing a couple other guys to help get Bob back to base for proper treatment. Water, rest, maybe an ambulance is called… depends on the situation. And, yeah, the tools he checked out all get brought back to be checked in for when he returns.
This will require some form of that Mesh Networking system that DeWALT threatened to release several years back, now a more common technology than it was back then. Also mobile devices with proprietary tracker and activation software for the tracker bands. Plus it’s going to have to get licensing with all the Safety agencies globally, so insurance can be adjusted for those companies that make use of them, as appropriate.
It’s truly the last place to go now. Site integration and User Health systems. This will have to include Mobile technologies like Mobile Phones and Smartwatches. Even fully dedicated PCs and Tablets for some functions. But it’ll be up to the tool companies to make and engineer the tool cart systems that integrate check-in, check-out, and logging of tracker bracelets along the way.
Everything else it could possibly be will be more of the same right now. A lot of companies are still trying to change and pivot their offerings to adapt to all the shortfalls the world economic situation has had to deal with since the 2008 financial crisis, renegotiation of the NAFTA agreement, and most recently the Covid 2020/21 work stoppages. Once they figure out where we’re using tools again, they can work toward getting on track to progress and innovation again.
I see that as a pretty optimistic view of things, I might add. I don’t see anything bleak about companies using active purchasing to see what’s going on with us users. It’s smart demographic experimentation, no matter how crazy it may seem.
Stuart
What if Bob puts down a tool because the task calls for something else to be used?
Some tool reporting makes sense, such as when crimped connections need to be done properly with sufficient pressure. There is a fast-approached limit where communications and data would be too complex and detailed to be analyzed or easily interpreted.
JoeM
All I can say to you and Matt below is, it’s just an example. I doubt anyone would use it if it was truly intrusive. But the first place my mind always goes when this particular avenue of development turns up is always first-aid and inventory.
Hell, with the press of a button, it could signal the need for a replacement battery be sent to a specific spot for continued use. Mobile technologies integrated into our tools, or mobile devices monitoring our tools, either way… Only thing I can see “Next” for Tool advancement is that.
Now, if you ask me what comes after Mobile Integration, I have a lot of faith in Nano-Graphine, Memory-Metal, and Piezo-Electric Pistons. Nano-Graphine would be batteries that suspend moving, or rotating, nano-fibres in an electrolyte solution in such a way that it rotates an embedded dynamo that generates power while idle, or while charging. Otherwise these meshes and grids of graphine would supply constant, reliable DC voltage from battery to tool, using a heat-free, and 90% weight reduced unit.
Piezo-Electric and Memory Metal applications for tools would likely have more to do with thermal reclamation of energy more than anything, though the energy required to operate these technologies isn’t even remotely as high as what we’re using today. Right now it’s limited to labs for proper development, but once it goes commercial level we can expect to need to learn a little bit of particle physics and quantum mechanics in order to explain how it works. Needless to say, this will end the era of “Unit Watts Out” once and for all, as there’s nothing in the use of Nano-Fibres or Graphine that can raise the cumulative output anywhere near the equation for watts. Electronvolts, Yes. Lasting for days, even years, of constant current? Definitely. But without these far-in-the-future developments, Tools will remain as they are, with tiny iterative improvements across dozens of model releases.
In the mean time… No… We wouldn’t be working for the tools, we’d simply have an entire worksite integrated. Safety, Security, and Inventory, all covered, with alerts and alarms set up for conditions workers and supervisors need to get. If Bob does drop a tool in his illness? It’ll get tracked by all the devices around it, and shown on a tablet somewhere.
Since we’re not seeing this right at this moment? I don’t think there is a “Next Big Thing” coming any time soon. We do have some recovery to do in the world right now, and a lot of tool companies have to take the time to survey the state of the world as it goes forward, rather than just continuing their usual paces. I see that as a good thing.
Matt
That sounds like hell on earth.
We will now work for the tool instead of vice versa
joseph
What I’d like to see is improvements on battery charging. You don’t need a big heavy battery if they charge ultra fast. I think we are currently being limited by the balance of runtime vs power. If runtime is less important it gives tool designers more room to work with.
MM
Faster charging would be great but there’s a pretty hard limit on it, and that’s the power which can be supplied by a normal wall outlet. In north America that’s technically 1800 watts tops before a 15 breaker trips. In practice 1500 watts seems like a a more reasonable maximum. Even if the battery has zero overheating issues and we can pump that full 1500 watts straight into the battery with zero losses (and this is a nonsensical assumption), it will still take a minimum time to charge the battery. If we assume an 18V 10Ah pack:
18V x 10Ah = 180 watt-hours = a little more than 7 minutes charge time.
And while that sounds pretty quick, it’s:
A) a slower rate than many tools can use the power in the battery, meaning you need multiple chargers to keep just one tool running
and
B) a baseline that will only get worse as larger and larger batteries become a thing.
This is the one area where gas powered tools still have an advantage: refueling is near instantaneous.
fred
If the battery/charger combination could circulate something other than air to cool the cells – really fast charging might be possible.
MM
This technology exists. Stuart mentioned something about Flex using phase-change materials for cooling their packs. I also have a friend who builds and races electric model speedboats. The battery packs he uses are made of flat (pouch) cells with aluminum plates in between each cell. These aluminum plates have hollow passages down the edges which circulate water to keep the pack cool. In this case it’s for preventing the battery from overheating under high current draw but there’s no reason something similar couldn’t be done for charging. The motors are likewise cooled with water jackets or coils around them.
But no matter how good cooling tech gets, there still exists the hard limit of the power which comes out of a wall outlet–something which many cordless tools have already exceeded.
Farmerguy
Worksite microwave, refrigerator, hot plate- crossover to camping
Autonomous worksite vehicles to help with parts retrieval, surveying, quality control
As quick charging tech moves into tools I can see tools with permanent batteries (replaceable when worn,but enclosed to save weight, best electrical connection, and water/dust tolerance)
My never gonna happen wish list is for interchangeability across brands. Skid steer loader attachment standardized years ago so it could happen
Chuck
Makita has an 18v coffee maker, but people complain about it taking too much power. Better batteries or more efficient heating can overcome this.
If they can put out a good “generator”, then people can use whichever fridge or appliance on the jobsite without issue. Dewalt has a decent 1500w power station, but that is still s.all compared to what people may want to use it for.
MM
Bigger batteries is really the only solution there. Electric heating is extremely efficient already. The problem is physics: water has a very high specific heat and also a very high heat of vaporization. It simply takes a lot of energy to heat and boil water, which is why it’s so effective as a coolant and why steam engines can be so powerful.
The “generator” things are coming. I a week ago one of the Youtube channels I follow suddenly had a product placement for a portable battery-powered “generator”. They demonstrated it running a refrigerator and a microwave, among other things, simultaneously.
MT_Noob
I’m glad to see that capacity keeps growing. In fact I recently came across a sale on a bosch 6.a pack for their 12 volt system that I didn’t even realize was available. It is a slightly different form factor, but it works just fine for my needs.
https://www.amazon.com/gp/product/B079NWHS9T
I’m fine with a smaller sized pack most of the time, but I like also having one larger one ready to go if for some reason I need more run time and don’t want to be swapping out muiltiple times.
Steve
I would like to see EGO come up with a battery powered pressure washer or a battery powered wheelbarrow.
MM
Battery powered wheelbarrows, carts, and dollies will be huge labor- and injury-savers. I believe that Makita already has a wheelbarrow which can also be configured as a cart that runs on it’s 18V LXT platform. I’ve never used one, and I’d have to guess the power is fairly marginal on an 18V platform, but it’s only a matter of time before they become a lot more common. There are already wheelbarrows as well as mini dump carts with a self-tipping hopper on them which are powered by gas engines, so it’s only a matter of time before these go electric. Same with those stand-on mini skid loaders. A cordless powered base for your toughsystem or packout gear, perhaps?
A cool idea would be to use multiple electric dollies for moving heavy items like furniture or machinery. A dolly with its own battery, motor, gearbox, and wheels is placed under each leg or corner of the item to be moved. The dollies all “talk” to each other via bluetooth and are controlled by a remote or perhaps by an app, and drive to move the heavy items around, rotate, level, etc. They could be made modular to combine units to move heavier loads. this could start with things like appliances and tables but could be scaled up to pallets of construction materials or heavy machinery.
John
First I think it’s an interesting time to be experiencing powered tools. Even from 10 years ago we had no idea we’d be where we are with cordless tools. My background is in electrical engineering and I work in the semiconductor industry. So my comments are based on what I see in my industry and where it can relate with power tools.
I think the next evolution is going to have more global constraints and it should push some interesting innovation. The next ten years is going to bring some massive changes globally. California has said by 2030 no new ice vehicles which is right around the corner honestly
If you look at other policies elsewhere in the world its a similar time line. What this means is there’s going to be competition for the resources. To suddenly replace hundreds of millions of vehicles is going to require a monumental amount of lithium batteries and lithium in general. While there is a lot of exciting and interesting battery advancements, in way of chemistry etc, around the door none are ready for application in power tools let alone vehicles and other applications like that. For instance the Japanese manufacturer Murata is planning on releasing a low voltage 25mah solid state battery by the end of this year. They are looking to produce about 10k per month. An application for this would be a backup battery for a system on chip or other tiny integrated circuits. It’s a great step forward for solid state batteries but still a long way off for everyday practical usage. So I think in general for most uses we’re stuck on lithium for at least 10 to 20 more years. What might be really interesting is tool manufacturers might be the first usage cases for alternative forms of batteries and energy storage or they may lead some innovation there because of smaller demands overall versus trying to electrify the world.
A lot of the new changes I think we are going to see is higher voltage systems becoming the defacto standard. You can’t beat physics and there will be a limit soon of how much we can get out of 18v to 24v for bigger tools. Honestly 18v to 24v might become what 12v is today. I think there’s going to be a lot of usability changes too to make things better in that regard. We’ll probably see a lot of gimmicky stuff too.
I would personally like to see a company design cordless tools of much higher caliber. If we could get metal bodied tools that would last a lot longer with likewise internals. If a company could release tools like this that were engineered to be upgraded when a new type of motor or battery comes out it would interesting. I know it’s a pipe dream but let’s make things that weren’t made to be throwaways like tools used to be. I’d pay a pretty penny for this honestly. I think in the far future this might be what we have to do with resources dwindling but it’s only a guess.
MM
You raise an interesting point about the tools of “higher caliber”. I tend to prefer high quality tools that are built to a high standard, will withstand abuse, and will last. It’s not that I abuse my tools, rather that I’d rather work an overpowered tool lightly than risk injury to myself, the work, or the tool by using a tool that’s inadequate for the job. I’ve often looked back at some of the older power tools made with aluminum housings, metal gears, chain drives, etc, as opposed to modern plastic everything and thought the older tools were built much tougher.
But when I think more about it I’m not so sure those last-forever tools are necessarily a good idea. Many years ago I was building a set of custom loudspeaker boxes. A friend of mine in college had a father who was seriously into woodworking as a hobby and pulled some strings to let me work in his dad’s private shop. I was very thankful. One evening while I was using his ancient aluminum-bodied Craftsman jigsaw its gearbox exploded, sending bits of housing and gears all around the shop. Whether the saw was just worn out and finally had enough, or whether it couldn’t handle cutting 2″ thick MDF I don’t know. Luckily my hand was not in the way and I had safety glasses on. I immediately explained what happened, apologized, and offered to buy a new saw. He would have nothing of it, and was in fact happy about the situation since this was now an excuse for him to get a new saw without his wife nagging him about buying too many new tools. He gave me his credit card and sent me to HD to buy a new one. I picked up the Porter Cable he said he wanted and went back to work. And you know what? It blew away that old Craftsman in every way. It was lighter, much better ergonomics, better speed control with the trigger, less vibration, more power, much easier and more secure blade change, and it made a straighter, smoother cut. Plus it had an orbiting feature (not that I needed it for my work). The old saw may have lasted a lot longer than I suspect that Porter Cable might, but it didn’t really deliver as much of a benefit to the user either.
Thus I think sometimes it makes sense that tools don’t last forever as in some cases the new technology vastly outperforms the old.
Of course that isn’t always true, I doubt you could buy a new drill press today that could compete with my old Carlton radial at any price. Nobody has made a manual milling machine in decades that can match an old Kearney & Trecker TF series or a precision lathe that can compete with a Monarch 10EE, etc.
Stuart
Regarding voltages, that’s a tough one, as 5-cell 18V batteries provide very substantial benefits when it comes to lower weight and compact size. We might see 21700-sized battery packs replace 10-cell 18650 batteries, but there are still pricing advantages not to mention greater consumer familiarity.
Makita is trying to go the “36V in an 18V battery size” route, but they also didn’t have a choice. They needed to free themselves of 18V system constraints, and launching a separate 20V Max line would have led existing 18V users to feel abandoned. Several brands did similar with less developed 18V systems when adopting Li-ion tech, and Makita’s current 18V system is several times larger.
Metabo HPT has the right idea, with MultiVolt batteries that can work on 36V or 18V tools, and there are still compact batteries that can be used with the 18V tools when lower size and weight are prioritized interests.
Dewalt did something similar with 20V Max and FlexVolt, although they seem to be pivoting slightly, giving users the option to go with 20V Max OR FlexVolt batteries, whereas current FlexVolt tools require FlexVolt batteries without exception.
12V Max tools are more popular than ever, but a lot of users would still sooner opt for a compact 18V model. First, there’s the perception of more power and performance even thought it’s not always true, but it also opens the door to larger systems of tools and accessories.
There are so many ways that the industry can branch off from where things are now, but consumer preferences and shopping habits always ends up steering the ship.
Regarding metal bodied tools, this adds to weight and costs, and I’m not sure that’s a direction users or shoppers would prefer. Well-made plastic-bodied tools last a very long time when treated well.
As for upgradeable tools, that wouldn’t work very well. A lot of times, components aren’t simply upgraded, everything is upgraded. Sometimes you can upgrade a computer with a new drop-in CPU upgrade, other times you need an all new motherboard to support generational upgrades. Consider the concept of a modular laptop. Another company is giving it a try, but this has been a concept that just hasn’t panned out yet.
There are some modular tools that allow you to connect different power base handles to various cutting, drilling, and sanding attachments, but this has been more of a money-saving DIYer concept that rises and drops in popularity every few years.
fred
Build-quality seems to have taken somewhat of a back seat to advancing technology. I don’t think that both combined are not possible – but the entire market seems to be more driven by price than in the psst. Maybe its a lament of old age – or just nostalgia – but I think that my Leica M3 and then M4 were better built cameras than anything I can purchase today. That’s not to say that I use my M4 or Nikon F2 a lot in place of the Canon digital camera that I find way more convenient and useful when travelling. Its just that I’ve gone through several digital cameras (Panasonic, Canon, Leica and Nikon) that have failed and were not really serviceable based on cost versus features and cost of replacements.
With tools – I’ve commented about the build quality and longevity of my Porter Cable 503 chain-drive sander – and my B&D supersawcat sidewinder saw with blade brake. I think that these are examples (for their time) of manufacturers attempting to produce the highest caliber tool that was within their capability. I wonder what a modern technology equivalent to these tools would cost and how well they might sell. My Unisaw cost me about $1000 delivered in early 1970’s – that’s equivalent to about $7000 today – but a new one costs about half of that suggesting that some economies must have been taken somewhere along the parts-to-manufacture-to-sales-to-delivery chain.
Chris
I can’t wait to see what new battery technology companies introduce next. Graphene batteries are certainly still something to be excited about, but at this point, it’s been like 5 years since I first heard about them, and only heard of CAT brand tools using them, but haven’t even heard any more about them since.
Franco Calcagni
“Earlier cordless grinders were simply described as cut-off tools. Why? I was told that it’s because they didn’t deliver enough power or runtime to be advertised for cordless grinding applications. ”
I just wanted to add to this that the earlier grinders, going from a cutoff wheel (think thin and light) to a masonry or steel grinding stone, 1/8 to 1/4″ wheel, the sheer weight spinning would blow the fuse/interupter or possibly burn the motor if it didn’t have protection.
James C
Don’t forget, innovations and new tools generally only come to market if companies think there is profit to be made. Along those lines many tool companies have very close relationships with select retailers and that can surely influence what comes to market as well.
Stacey Jones
I think it’d be cool if you could piggy back connect batteries like legos, so take 2 20v packs, flip a switch to put them in series and you’ve got 40v, flip it the other way and they are in parallel and you’ve got twice the capacity. Also, why can’t we open the pack and pop in cells like we do with alkaline? Probably afraid folks will pop them in backwards and start a fire…
Mr. X
Automation, Miniaturization, and Innovation.
Look for smaller but still powerful tools that will perform many of the duties of hand held tools. Think: stripping or splicing wires, crimping pro-press plumbing fittings, adjustable wrenches that auto size, stripping the metal covering of MC cable, compact pipe threaders, and hole punches, all in the palm of your hand. Also look for AI to take advantage of this available power. Imagine a motorized job box that gets dropped off on site and finds its way to the work location or a CNC enabled miter saw that sets all angles for a compound cut. Finally, I foresee cordless tools that will be smart with battery use to extend run-time. Imagine a vac that senses the waste being sucked up ad automatically adjusts the motor speed for top efficiency or a saw that determines the best reciprocation rate based on the inserted blade and material being cut.
One thing I am sure of is that the best innovation is something nobody is even thinking about right now…
Chris
Eric
Car battery interface. Imagine the run time. Plus if you need more power run 2 or even 3 in series and have twice or thrice the power with no sacrifice in run time. Plus they aren’t much larger than the Milwaukee MX or the 15AH batteries.
Dust
Worth noting SBD had made investments in next gen battery tech. Prieto batteries that use a copper foam. I think we’ll see next gen tool batteries in a few years. Maybe as a premium option.
Batteries are really what’s holding cordless back. Even if the power is there, no one can make high demand tools that don’t nt overheat easily.
Kevin
It’s all about the batteries. I think the when it becomes financially viable (this is way out in the future) I predict we’ll see a new industry standard battery chemistry. Lithium ion will probably be replaced with something like solid state. Also with battery powered tools, the increase in power is virtually limitless, with the only limiting factor being how much power the batteries can deliver. Corded is limited to what 1800 watts. As long as the battery chemistry can supply the power, they can make tools proportionately more powerful.
Rx9
Short term:
-More cordless outdoor power equipment
-More smartphone integration
-Lighter, smaller form factors
-Another new battery system, destined to be orphaned within 2 years
Medium term:
-Durable small touchscreens on tools
-Universal battery systems
-Nanotech enhanced consumables (drill bits, saw blades, etc .)
-Specialty material construction as a mainstream marketing point – carbon fiber, inconel, titanium, Kevlar, etc.
Longer term:
-Machine learning-based frame designs
-Fuel cell cordless power
-Considerably more affordable specialty diagnostic tools- ultrasound, thermal vision, 3d scanning, chemical analyzers, etc.
Distant term:
-Orbital service ratings
-AI gyroscopic stabilizers
-Metamaterial construction
-Mind link interface
In every period in the past and future:
-Both early adopters and hold-outs
-Marketing hype and subsequent disappointment
-Quality engineering worthy of respect and adoration
-Rent seeking efforts by manufacturers
-Enthusiasts subverting those manufacturers’ efforts
-The satisfaction of a job well done, partially thanks to having the right tools
Matt J.
I’m expecting to see more AI integration into tools. I’m sure there are tons of applications, but think about a jigsaw with a camera pack that can move it’s blade to follow complex layout lines? Or saws that can detect a finger or other unintended object in a blade path? My robot vacuum has cameras that can detect, recognize, and avoid dog poop or other similar messes…I feel like even if it’s not 100% perfect, we’ll start seeing this kind of tech creep in. Probably the next “laser cut line” that ends up getting slapped on everything but implemented poorly more often than done in a way that is helpful for pros, but there’s potential.
bobad
I’ve been hoping for a 20v Dremel-type rotary tool with brushless motor. The cordless rotary tools currently on the market are awful. The best of the bunch is Milwaukee, but the standard battery has low capacity and the collet is a pipsqueak. Maybe Makita, DeWalt, or Rigid will come to the rescue.
MM
Try a “die grinder” instead. The M12 ones are pretty nice actually, and you have your choice of straight or 90 degree.
Frank Campbell
nice but still low power supply
bobad
Looked at them already, good possibilities but some problems, including bulk and fast battery drain on smaller batteries. Thanks!
MM
The runtime depends on the load on the tool. These are generally used for much harder work than a “Dremel”. If you use them like you would a dremel with the smaller dremel-size bits the runtime is much longer than would be expected with normal die-grinding operations.
Nathan
So a few things I see.
1 – high voltage yields lower current = lower heat creation. will work for a while for some – I read quite a bit how the flexvolt concete saw works better than the milwaukee. but that only goes so far
2_ better motor controllers – advances is brushless motor control I think still have a bit to go.
3 – forced cooling. Liquid cooling for the tools withp otential for liquid cooling for the batteries. figure a in and out port on a battery – it has liquid in it too. some tools have the port to push fluid though – some might not need it.
4 – more bt wifi integrations – not just tool tracking which is being asked for. but also features. IR does this now on a lot of their tools. things like – record torque sets – set torque by software – count tool activations, etc etc.
5 – more cordless tools – big things like cordless welders, etc. more cordless power stations. but also like said before I’d like to see more assister things. Motor cordless dolly, etc.
6 – within the next 10 years I wonder if we will see a trend to environmental sustainability with better batter recycling.
Perry
I think we’ll see successfull attempts at wireless charging, and more “lifestyle” integration like we see in other countries (makita fridge/bicycle/ cart/coffeemaker, Milwaukee heated jackets, ryobi coolers that came out in Australia 1st) .
The wireless integration would mean a battery upgrade with existing tools, amd lifestyle integration means buyers have more reason to lock in with one brand.
Either of those also make allowances for several avenues of the “what’s next in battery tech?” That we dont have an answer for yet. We know that battery chemistry is going to change, we just don’t know what the next big thing is, which is where I think the manufacturers are waiting.
Oleg K
Solid state batteries, smaller, more powerful brushless motors would be my guess,however, since power tools are meant to be sold at profit, my guess is that the manufacturers will end up making everything cheaper/smaller. Solid State batteries will find their way into cordless tolls in about a decade, once the technklogy matures and becomes cheaper, I believe that the leading, most mainstream manufacturers will also concentrate on adding more features to drills and such, also improving connectivity (IOT segment) and interoperability of tools. I also think that, in the end, there will be only three or four bug companies sharing the monopoly on power tools with smaller guys dying off.
Mike
I think lithium battery technology has pretty much peaked, its time for new battery technology if they want to go forward because lithium is not the answer
SpainUser
Well, as far as battery is concerned, Li-ion is roughly at 450 Wh/kg density, with it’s their last limit roughly at 800 Wh/kg and current 21700 cell package closer to the 300 Wh/kg range with is price reduction is manufacturing that will accelerate lowering the cost as soon as impose lithium recovery starts in 2022-23, then I’d say the current platforms of batteries will continue to deliver longer endurece times and will drive more and more for tools to be cordless rather than corded. Amperage output is a key metric of how powerful the tool can be, and we will see some improvement there over time. Electric cars will certainly drive us to the 480+Wh/kg density and that is a plus for us, basically getting the same runtime of a 9-12Ah on a 4Ah battery package size surely is motivating for tool manufactures.
From a power perspective, this advancement in runtime will also allow for faster charge cycles, and that will be a plus to run cordless all day long.
While it has not started to happen yet, interconnect tools and tool health cloud base solutions will take off. I hate the use of AI, when in reality is machine learning, so there is lot’s happening on that space to not only build the tools, but also to service them. More on that front will be combing on the later half of this year.
Some have mentioned it, CFR material usage will improve, making some tools lighter and allowing for new from factors. Yes the tools will get more plastic, but the hope is that the plastic will out last the metal. :). Yet to see how this develops. Think of a hack saw or a job site table saw weighing in at 10-20kg, on wheels…
Contrary to some of the comments, there is lots of advancements ( almost at peak) from the electronics side of BL motor tech, very straight forward to be honest. So expect some improvement in size (mostly on the motor material improvements) On the corded side, PMAC will start to make the seen for smaller tools also, and it will challenge the innovation of cordless, this improving the Time to Market, ie, smaller more powerful cordless tools with innovation on the BLDC motors.
We will see lot’s of safety features, like anti kick back on saws and drill, but also what I’m calling assisted deployment for a last of a term, where you will have, say a drill, the shaft and motor sit on a housing internal to the tool, and you just set the depth and an angle, lay the tool with assisted pointer to the surface, press the trigger, and the drill will deploy and adjust for movement to align for movement and depth.
Also, we will see “lots” of power tools in the form of had tools. Think of power screw drivers and and had saws… 🙂