DeWALT has officially announced their new 20V Max* PowerStack 5Ah battery, DCBP520, which will be launching in the USA next month.
As with the brand’s 1.7Ah PowerStack battery, the new 5Ah battery is engineered with Li-ion pouch battery cells, and not the cylindrical cells found in most other cordless power tool battery packs.
I have been talking with DeWALT about some of the engineering that went into the new PowerStack 5Ah battery, and definitely learned more than I expected to.
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NOTE: DeWALT is sponsoring ToolGuyd’s exploration and coverage of the PowerStack 5Ah battery.
In this post, I will be discussing some of the questions I asked and the answers I was given. Please let me know if you have any other questions, and I will try my best to get them answered for you.
If you are looking to get up to speed on the basics of DeWALT PowerStack pouch cell technology, consider reading these posts first:
Next-Gen Dewalt POWERSTACK Cordless Power Tool Battery
Dewalt is Launching a New PowerStack 5Ah Battery!
What is New About this PowerStack Battery?
This new PowerStack 5Ah battery delivers 50% more power¹ and 50% more work per charge², compared to their cylindrical-cell 5Ah battery, and also has 2X the lifespan³.
¹compared to DEWALT DCB205 battery, not in application
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²based on usable energy vs. DEWALT DCB205 battery, not in application
³based on charge cycles vs. DEWALT DCB205 battery
DeWALT launched their first 20V Max* PowerStack battery towards the end of 2021. That battery was designed to provide significant size and weight benefits compared to the brand’s compact batteries built with cylindrical cells.
With this new PowerStack 5Ah battery, the focus is on power and efficiency.
How Did DeWALT Make a Bigger PowerStack Battery?
When talking about cordless power tool batteries engineered with cylindrical Li-ion cells, there are different ways a tool brand can increase charge capacity. Generally speaking, they can select higher capacity cells, add more cells, physically increasing the size of the battery pack, or do both.
With pouch battery packs, new battery cells must be developed.
Basically, the Li-ion pouch battery cells in the PowerStack 5Ah battery were engineered specifically for this battery pack.
What I Didn’t Think About Before
18650-sized Li-ion battery cells – and now 21700-sized cells – were never designed specifically for cordless power tools.
Tool makers have long-relied on cylindrical battery cells because they were convenient and available.
Improvements in the cylindrical battery cell industry drove improvements in cordless power tool battery packs.
But with PowerStack, everything has changed.
DeWALT says (with emphasis my own) that they are:
The world’s first major power tool brand to use pouch cell batteries designed for the construction industry.
The batteries are custom-built specifically for cordless power tool applications.
They are spec’ed for power tool use.
There are significant benefits when comparing PowerStack pouch cells to cylindrical cells, such as lower internal impedance – which keeps the batteries running cooler – and more efficient connections.
The PowerStack batteries were designed for todays’ high-demand cordless power tools.
How Does the PowerStack 5Ah Battery Deliver 50% More Work Done per Charge?
Simply put, there are lower heat losses, which means more of a PowerStack battery pack’s charge capacity can go towards getting work done.
As I understand it, the PowerStack battery will keep going under demanding conditions, whereas a battery with cylindrical cells might have drained more quickly – if it didn’t shut down due to thermal overload conditions.
How is the PowerStack 5Ah Battery More Powerful?
As mentioned, PowerStack battery cells are custom-built specifically for cordless power tool applications.
Because of this, its properties can be dialed-in.
With DeWALT’s first PowerStack battery, the goal was to shed size and weight to deliver a more compact pack.
Here, the goal was for a balance between power, runtime, and longevity.
Because the pouch cells feature a lower energy density, that helps them run cooler while also being able to deliver higher performance.
Do PowerStack Batteries Require a Special Charger?
No – you can charge PowerStack batteries on any DeWALT 20V Max* charger.
Part of the reason for this is because PowerStack battery packs are in fact built with Li-ion battery cells.
You can charge, use, or store PowerStack batteries in the same manner as any other DeWALT 20V Max* batteries.
Additionally, the PowerStack 5Ah battery has a protective non-marring overmolded base, and a fuel gauge.
Will it Boost the Performance of DeWALT 20V Max* Cordless Power Tools?
Actually, yes!
The PowerStack 5Ah battery will help unlock the full performance potential of the brand’s 20V Max* Power Detect cordless power tools.
Are there any Other Benefits?
Yes!
The way the PowerStack 5Ah battery is designed, there are 5 Li-ion cells connected in series, similar to the brand’s compact cylindrical-cell batteries. This would ordinarily limit them to a maximum charging rate of 4A.
However, the PowerStack 5Ah battery design allows it to recharge at a rate of up to 8A.
Are They Safe?
Safety is obviously a big concern for everyone.
I have been assured that the new battery has undergone thorough and robust testing, and can be treated in exactly the same manner as DeWALT’s other 20V Max* batteries.
The compact PowerStack battery has also been on the market and in users’ hands for about a year now.
How Does this Change Things?
Ever since I spoke with DeWALT about the engineering that went into the PowerStack 5Ah battery, and how it differs from their existing 20V Max* batteries, I cannot help but think of the words – “the proper tool for the job.”
It’s kind of like how everything and anything can be a hammer in a pinch, but a true hammer will deliver the best performance. Or, how a slotted screwdriver can be a prying tool, albeit with less than ideal results.
Cordless power tool brands all did a great job getting to where we are today using what in most cases are off-the-shelf cylindrical battery cells.
But now, for the first time, we’ve got new cordless power tool batteries designed specifically for the “cordless jobsite” that tool brands have been pushing towards over the past few years.
PowerStack batteries are pricier, but this can be offset with their claims of greater longevity.
Improvements in cordless power tool and battery capabilities have driven the industry forward in a progressive manner over the past few years.
In the nearly 14 years since I started ToolGuyd, I have reported on all of the gradual increases in battery pack charge capacity, the jump from 18650 to 21700-sized Li-ion cells, the introduction of brushless motors and higher voltage cordless systems, and more.
This is brand new territory, and definitely exciting times.
How Much Will it Cost?
DCBP520 (Single Battery) – $229
DCBP20C (Starter Kit) – $289
DCBP20-2 (2-Pack) – $349
ETA: The new battery will be launching at DeWALT tool dealers in the USA in December 2022.
Do You Have Any Questions?
I am extremely excited to see what the new PowerStack 5Ah battery can do, and will be putting it through extensive testing.
Please let me know if you have any questions or requests!
*Maximum initial battery voltage (measured without a workload) is 20 volts. Nominal voltage is
18.
Jared
What does “not in application” mean with respect to the power and capacity claims?
I presume the claim that the Powerstack pack offers 50% more work over the 18650 pack with the same 5ah rating is true only in applications where the 18650 is being drained quickly and generating substantial heat?
Otherwise I don’t understand how it can have the same capacity and do more with it. E.g. a grinder or a blower ought to see runtime gains, but would a flashlight run 50% longer? That seems unlikely.
I am looking forward to the new pack though! It sure looks promising.
Stuart
My interpretation is similar to yours, that real-world performance can vary.
For instance, there will likely be differences between using an LED flashlight on low power, and a circular saw to cut through stacks of plywood or an LVL beam.
I have my work cut out for me in testing the battery. The 1.7Ah PowerStack is very nice – I own more than one now, in addition to having test samples. But the 5Ah – I think it’s going to be a gamechanger.
Tech
Then does the 5ah powerstack on flashlight burn faster than a regular 5ah?
Stuart
I don’t see why it would.
5Ah is the charge capacity.
Under low demands, two 5Ah batteries of different styles, such as with cylindrical cells and pouch cells, should deliver approximately the same runtime.
Under higher demands, two 5Ah batteries as described will usually perform differently. The battery with higher power capabilities and higher efficiency – the PowerStack 5Ah – should last longer.
At higher power delivery, batteries with greater internal resistance will heat up faster and maybe even hotter, leading to greater energy losses. Heat is energy lost to the environment, whereas a more efficiency battery that stays cooler has more energy to contribute towards work being done.
Let’s say an Olympic sprinter is paired up with an average person. Both can walk 5 miles before taking a break. Will you be able to tell the Olympic runner from their companion? Maybe not. Now, ask them to race 400 meters. You’re going to be able to see the difference really fast.
John+E
I ran “not in application” through a marketing B.S. detector and it spat out “on paper”.
Collin
The Power stack should run cooler in high wattage applications, so fewer thermal lockouts= more work done.
Also, lithium ion batteries discharge curves vary with temperature. Too cold and the battery will appear to have very little capacity even when fully charged. Too hot, same thing. These Power stack batteries can get more work done by staying within the optimum temperature range.
jason Gloekler
Ive converted most of my smaller AH batteries to powerstack and the weight savings/ size, plus increased power on smaller tools, has been a worthwhile investment. And to add that they should last longer is a big plus.
MM
This is good news indeed. I just picked up a couple of 15ah Flexvolts to keep my large tool needs taken care of, and now these new 5ah Power Stacks can replace many of my old 4ah packs from when I first bought into 20V max back in 2013-2014. I still have several batts from back then which are getting a bit long in the tooth, and I’ve been holding out for these to replace them.
I am curious what other size Power Stack batteries Dewalt has planned. Is a larger size model in the works, like maybe a 10ah? What about Flexvolt versions of this technology?
Stuart
Dewalt could not discuss future plans with me, but I believe there’s huge potential here.
Big Richard
A 2p 10Ah version of this pack would be a strong candidate. The 5000mAh cells they use in the current XR 10Ah DCB210 packs just don’t have enough sauce. They have to run them at the very edge of their capability to get the performance they want, and it seems to lead to failures. While I have four of them with zero issues, they seem to have quite the negative reviews from people cooking them in the mower that they came kitted with.
So a true high powered 10Ah would be a nice addition. And I have to think a FlexVolt option is in the works, too.
MM
I agree, double up the packs from the 5ah in parallel, should provide some serious juice.
I have two of those DCB210s that came with the mower. I’ve used them in the mower, angle grinder, and the 7 1/4 miter saw. So far they’ve been working fine for me, though I only use the mower for small areas my big ZTR won’t fit in so I’ve never run it hard for more than 5 minutes at a time.
Lyle
I can’t wait to see what promotions come out to try to get these batteries out in the wild. The individual pricing seems a bit high so I’m gonna wait until these are bundled with tools and then I’m gonna be buying a bunch of bundles and sell off the tools. Also gonna be selling about 8 5Ah batteries when I can. I’ve been really happy with the 1.7Ah version so I can’t wait for the 5Ah and hopefully in the future they develop a FlexVolt version.
Steven L
PowerStack has improvements but is there is value?
Today I can buy two DCB205s for $140 – $14.00 / Ah. The Black Friday battery deal for $199 plus two free DCB205s will cost me $9.95 / Ah.
The Powerstack 5Ah two pack will cost $349 – $34.90 / Ah.
I don’t see a reason to pay $35 / Ah. Am I missing something or will pricing have to change??
MM
For starters you’re comparing black friday sale prices with MSRP of a brand new product, of course there will be differences. No doubt the new batteries will have promos as well, just like the earlier 1.7ah powerstacks. The list price on a 1.7ah powerstack is $119 but they’re currently on sale for $59 at Farm & Fleet, so about half MSRP. The two I picked up were part of promos that cost roughly the same. If that same sort of pricing extends to the 5ah we could see those for $17 per ah, a big difference from $35.
Whether or not that difference is worth it really depends on what you’re doing. For some tasks the powerstacks are fantastic, for others they’re no better than standard packs. I’ve had two of the 1.7ah Flexvolts for a while now, for something like a 15ga nailer they’re a bit silly in my opinion, the nailer doesn’t benefit from the extra power, and even a standard battery is tiny compared to the size and weight of the tool so the powerstack offers no real advantage. Now on the other hand, take a compact impact wrench or the multi-material cutoff saw for an automotive application, trying to reach transmission bolts or cutting off a rusty exhaust hanger…now that tiny but powerful powerstack batt is worth every penny and then some. Whether or not these batteries are worth the price is something that every tool owner is going to have to decide on their specific needs.
MoogleMan3
I’d love to see a 3ah version of the powerstack that has the same footprint as the 1.7, just a bit taller.
Big Richard
Theoretically they could make a 2p version of that pack and it would be 3.4Ah, and as you said a bit taller. It would probably be about as tall as the 5Ah, just with the smaller footprint of the 1.7Ah.
MoogleMan3
That would be a killer battery. The 1.7 already has the power of a 5.0 18650, just lacks a bit in runtime.
Sash
In theory they can do that, but being custom pouch cells, they would be better of using bigger cells. Bigger pouches as such. The issues with a lot of the batteries these days is the BMS – Battery managemet system. The circuit board int he battery. Once you stack the batteries the BMS sees the 2 stacked batteries as one battery, and charges as such. This is where you get a dead cells, as one could be normal voltage, and the other dead. Then the whole pack is dead. If you stay at 5 cells, and make them higher mah rating (bigger pouches) you can draw the more current you need, and also control the charge to the individual cells better and make sure you balance the voltage of the cells out. I would say this is where they are getting twice the life of the cylindrical cells as they are balance charging them.
Peter
I might have missed it but what about the weight?
Thank you.
James
If dewalt claims the battery will have greater longevity, do they reflect that in their battery warranty?
Andrew
They did in the UK, PS 5ah has a 3 year warranty. Rest of Dewalt batteries get a 1 year warranty, For the UK
Big Richard
So you didn’t ask about the little tabs/knobs, or horns as you called them?
Stuart
I forgot to, but still plan to.
The tabs are not unique to the PowerStack 5Ah battery; similar structural features are found on Dewalt FlexVolt batteries, as well as 21700-cell-equipped 20V Max batteries (e.g. 6Ah).
Big Richard
The FV and high capacity XR packs do have a ridge of sorts on them, but it is much more subtle and runs the length of the pack, looks more like it is there to give the case some strength as most of the pack’s weight is below the tool connection area. These are just little knobs. Maybe it is purely aesthetics, they thought it made the pack look faster, who knows. Just curious is all.
Miguel
“ Li-ion pouch battery cells in the PowerStack”
Can you confirm that the electrolyte is Li-ion because it usually is LiPo.
Stuart
I can confirm this; I asked and was explicitly informed that Dewalt PowerStack battery packs are engineered with Li-ion pouch cells.
Doug Fletcher
Li-ios and LiPo are both extremely generic terms that do not tell you about at batteries specific chemistry. LiPo just refers to a Li-ion battery in a polymer case (usually pouch). The chemistry in a LiPo cell will be basically the same as a cylindrical cell its just packed differently.
Stuart
The “polymer” part in Lithium-ion polymer batteries traditionally refers to the electrolyte material, not the foil wrapper.
Nathan
so will there be a smaller lighter say 2.5AH battery? Seems fitting
as would a 3-4Ah Flexvolt in the works. that could be very interesting for use like the larger rotary hammer.
or other things. Figure this will expand and cheapen over time. I mean I wonder what the pricing of the first LIPO battery sets where as adjusted for inflation.
anyway interesting bits – also doesn’t Flex already have multiple pouch based battery sizes
MM
Yes, Flex currently has 3.5, 6.0, and 10.0ah pouch style batteries; they call them “Stacked Lithium”.
Mark M.
I’m trying to wrap my head around how to view these new batteries. As a long-time cordless tool user I know based on experience when I can get away with a 2ah battery and when I need a 5ah or 8 or 9 or whatever, either because of increased power/load or runtime or both.
With these new batteries, do you think it’s reasonable to now think of the 1.7 more like a traditional 3ah, and the 5.0 more like a 7 or 8ah? Are they really that good, or is the 5ah really more like a super solid 5ah. I’m not doing a good job of phrasing that but hopefully you see what I’m getting at.
MM
From my use of the 1.7ah Powerstacks I think of them as “the power/load capability of a 5ah, the runtime of a 2ah”. My guess would be these new 5 amp powerstacks would have the “power of a 10ah, runtime of a 5ah”
Mark M.
That’s exactly what I was looking for. Thanks!
Stuart
That’s a great way of putting it!
Stuart
It really depends on your individual needs, wants, and budget.
It’s too soon to say about the 5Ah, but I am emphatically fond of the PowerStack 1.7Ah battery. Dewalt sought out to make a more powerful, more compact, and lighter weight 20V Max battery compared to their DCB202 2Ah battery, and that is exactly what they accomplished. Not everyone wants or needs that. With the 5Ah, the comparative claims are clearly defined, you just need to judge whether if and how it will benefit your work or user experience.
AP
Very curious where other tool manufacturers are with this battery technology.
MM
Flex has 3.5, 6, and 10.0 ah “Stacked Lithium” batteries right now. We know that Milwaukee is working on theirs thanks to Stuart’s article from a few months ago, though there was no estimated release date. I’d assume that all the big players are working on this technology as it’s a logical step forward but as far as I know Flex and Dewalt are the only ones with the batteries on the market now.
AP
Thanks, MM. The Flex batteries are really nice. I hope Makita and Milwaukee come out swinging!
DrDoug
Stuart, you said that “Because the pouch cells feature a lower energy density, that helps them run cooler while also being able to deliver higher performance” which puzzles me… Wouldn’t the pouch cells require a higher energy density in order to have better performance for the weight and size of the pack?
Stuart
No. Higher energy density increases charge capacity.
Let’s say you have (10) 5-year olds playing in a small room. Add 10 more, and what happens to the noise level? What happens to the number of arguments, pushing, or fighting after a while?
Now, double the size of the room. What happens to the pushing, fighting, and other such interactions?
Lower energy density means less heat.
Generally, a top-of-the-line 18650 cell with 3Ah charge capacity is going to have higher energy density but lower max current delivery than a 2Ah battery.
When 18650 cells hit a tech ceiling, brands sought other solutions, such as 15-cell higher voltage or higher output-capable batteries.
When 21700 cells entered the scene, they offered lower energy density and then greater charge capacity with higher energy density, matching or beating what 18650 cells can do.
With pouch cells, a tool brand or battery maker has a lot more control. Charge density or energy density can influence factors such as cooling and max power output. The physical size can also then determine total charge capacity.
My understanding is that for any given size and weight of pouch battery, there are 3 levels of characteristics – max performance, max charge capacity, or balanced performance and charge capacity. You can determine which factor you want fixed, and control the other.
Clay
I am assuming the batteries themselves will stick to the DeWalt standard and not have overdraw protection on the batteries (since DeWalt puts that on their tool instead). Is that your understanding?
I am always reluctant to use my DeWalt batteries on other tools with an adapter because of this.
1day@atime
Good call on editing the post from what I saw yesterday from Dewalt regarding this battery. Dewalt are the first ones with battery pouch technology for cordless tools. They’re also the first to be completely full of sht in what they’re claiming about their pouch batteries. Comically ridiculous is the gist of what I gathered reading about it yesterday. This isn’t the ultimate breakthrough in battery technology by any stretch. I’m not go into slamming Dewalt for being full of sht. Its to be expected. But I do have some questions for Dewalt that I very much doubt they have answers for. But let’s see what happens.
What exactly do they mean by 50% more power? Power can mean several different things. Power meaning strength and speed? Power meaning power boost? Runtime? What power increases by 50% when using this battery? Does that power apply to every single 20v Dewalt cordless tool and does it apply to every single task that can be negotiated per 20v tool? And 50% more work per charge. What work? Cutting? Drilling? Demolition? Chipping concrete? 50% more of which type of work is Dewalt talking about? All tasks? What about when the battery is charging? Does it mean 50% less work is getting done using a different 5ah battery? Two times the life. This battery is brand new. No one knows how long these batteries will last yet. I have some normal Dewalt 20v batteries that are going on ten years and better. I have some that are a few years old. I don’t have any that are newer than two years old. They all work fine. They can also fail at any given time. So how can these pouch batteries have 2x the life when they’re brand spanking new? Fresh on the market with a fresh bunch of bullshit. It’s aggravating and completely unnecessary. To be honest it compels me to not buy a new Dewalt battery. Especially these batteries. Tell us what it is and let that be the end of it. A battery with new technology. That’s all we need. Nothing else. We can decide from there. The gimmicks are old and quite lame and are absolutely unnecessary. That’s my two cents.
Stuart
I didn’t make any edits; perhaps you are referring to my separate announcement post?
Here’s a rough analogy I hope will clear things up:
One pickup truck can tow 1.2-ton. Another pickup truck can tow 2.5 tons.
Let’s say they both have to tow 1/4 ton. is there a difference in the drive from point A to point B?
What about if the load is increased to 1/2 ton?
What about a 1-ton load? Exactly 1.2 ton? Now, what if the path from A to B is an incline?
Under higher load, the more capable pickup will perform closer to expectations while the other’s performance sags and maybe even struggles.
Longevity is usually rated with respect to how many charge/discharge cycles before charge capacity drops below a certain percent. That doesn’t mean a battery has failed.
Let’s say a hypothetical battery can be charged 100 times before its max charge capacity drops to 60%. If another hypothetical battery can be charged 200 times before its max charge capacity drops to 60%, it would have 2X the longevity. I picked 60% arbitrarily. Different brands and different users might have different ideas about what the percentage could be.
For smartphones these days, most people hope for all-day runtime from their battery. When their battery drops below a certain capability, they replace it. With many, you can keep going until a smartphone is taken off the charger at 8am and needs to be recharged by 10am. Does the battery still work? Yes. But is it still effective at doing its job?
At one point, a user might have one new battery that can do the job of many older batteries. Battery failure can happen, but wear is inevitable and unavoidable.
Hypothetically speaking – let’s say a 5Ah battery was a truck that could tow a 1 ton load. The PowerStack battery would be a truck that could tow a 1.5 ton load. If you need to tow 100 lbs, you might not see a difference. But if you have a 1 ton load and are driving up an incline, that’s where you’ll see it.
With both battery-truck hypotheticals, let’s say the 5Ah can get 15 miles per gallon when hauling a 1/4 ton load. The PowerStack 5Ah truck might also get 15 miles per gallon when hauling that load. But on flat ground with a 1 ton load, the 5Ah might drop to 10 miles per gallon while the PowerStack achieves the same 15.
Why? That requires an understanding of battery technologies and a bit of physics.
Scroll up and read my analogy about 5-year olds in a room. https://toolguyd.com/dewalt-powerstack-5ah-battery-answers/#comment-1473165 In a nutshell, the PowerStack 5Ah battery runs cooler under heavier loads.
It’s not a gimmick, it’s just a complex product you either have to understand in theory or experience in practice to fully appreciate. Even then, will it benefit YOU? That depends on the types of tools you use, and how.
Lyle
Stuart, my reply wasn’t meant towards you, but the person you were responding to.
Lyle
Wow, cynical aren’t we? The powerstack batteries are smaller and lighter, but can perform like much larger capacity batteries. If you understand the technology then you can understand it a bit better. You can watch a bunch of videos on YouTube where people compare the tiny 1.7Ah battery to various other capacity Dewalt batteries. I had a few 2Ah batteries that I would use on my drills and impact drivers. I preferred the smaller size and weight and didn’t need them to be “powerful”. When using a saw or something that required more power or longer run time, I’d use the 5Ah batteries and I have a bunch of those. After the powerstack battery came out, I sold all of my 2Ah batteries (except a super old one from 2013 that still works great) and bought 1.7Ah batteries as replacements. I now have 10 of them and I love them. They have the same power as the 5Ah batteries, but are much smaller and lighter. Will they last all day long? No, but neither do I. I’m just your average DIY person so if you want long runtime then these aren’t the right solution. The smaller capacity works for me because I’m at home and if my battery runs out, I just grab another one off another tool and slap the spent one on the charger. We’ll see how their claims of twice the longevity works out. Like I said, I have a 2Ah battery from 2013 that still works just fine. In fact all of the batteries that have gone bad were 5Ah ones, and I believe most of them just got drained too much for the charger to charge them. I will soon work on trying to recover them with a bench top power supply.
Kingsley
I bought one a few weeks ago here in the UK and was disappointed with its size considering it cost so much.
I sent it back.
William
Milwaukee owns lots of patents in power tool Li-ion battery system, Dewalt has to be aggresive in new battery technology. Lithium pouch cell haven’t been used in power tool before due to the cost and safety concern. I’m interested in how Dewalt fixing the problem of pouch cell expansion due to heat generated during application.
Paul
I would like to see 12v power stack batteries for more power and weight savings in the 12v line up.