Feature: Batteries
Shaping the future of power tool battery pack design
By Owen McNally, Principal Design Engineer, Alexander Battery Technologies
B
attery technology is driving the evolution of power tools. As manufacturers push for better performance and usability, the battery pack has become a key battleground. Designing a battery pack isn’t just about cramming in more energy, power tool OEMs need to strike a
balance between durability, power and safety, while keeping up with technological advancements and industry trends. Owen McNally, Principal Design Engineer at Alexander Battery Technologies, explores the key factors shaping next-generation battery packs for power tools.
26 April 2025
www.electronicsworld.co.uk
Balancing performance and durability in battery design Te challenges faced by manufacturers in the power tool industry largely depend on the type of tool and its end-use application. As any tool manufacturer will understand, a drill used occasionally for DIY projects doesn’t have the same demands as a high-powered impact wrench on a construction site and the batteries inside them need to reflect that. Designing batteries for professional tools comes with higher expectations for sustained power, thermal management and resilience against real-world conditions. A key distinction in battery design for power tools is the
difference in requirements between consumer-grade and professional-grade batteries. For consumer tools, cost-effectiveness and ease of use take priority. Tese tools are generally not subjected to heavy or prolonged use, so batteries don’t need to withstand constant high-power demands or extreme conditions. Instead, their design focuses on affordability, moderate durability and a straightforward user operation. However, professional tools demand far more from their batteries.
Tese tools are used on job sites where they can face harsh and unpredictable conditions. Teir batteries need to deliver sustained high power without overheating while also withstanding drops, dust and moisture. Battery design engineers will incorporate essential features like ruggedised casings, high discharge rates and efficient thermal management to ensure long-term reliability and high- performance standards in tough environments. Standardised battery platforms have helped OEMs simplify
power tool ecosystems, offering broad compatibility and ease of use. However, these solutions don’t always meet the needs of professional and industrial applications, where performance and durability are key. As operational demands become more specialised, many manufacturers are looking beyond off-the-shelf options towards tailored battery solutions designed for real-world conditions. For power tools used in extreme conditions, battery performance
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