Milwaukee Tool

New Product Developement - Batteries, Portable Power, and Chargers

New Battery Development
M18 Forge 12.0 Ah Battery

Projects

Non-Disclosure Agreement: I will only disclose non-proprietary information regarding my work at Milwaukee Tool. All images are public knowledge.

New Battery Development

Upon completing my master’s, I took the opportunity to work on Milwaukee Tool’s New Product Development team for batteries. I primarily work on the M18 Battery platform, but I have assisted teams on designs for the M12 and MX platforms.

Although I cannot disclose my most recent work, I have designed functional prototypes and hard tooled components for batteries including power routing, housings, buttons, power terminals, and cell cores. These designs were validated using hand calculations, simulations, and extensive testing. Through these projects, I’ve also gotten the opportunity to work with international teams both virtually and in-person at the company’s manufacturing facility in China.

I have designed components for high volume manufacturing, automation and ramped assembly.

Processes Utilized

Injection Molding

Sheet Metal Stamping & Bending

CNC Machining

Dip/Spray/Vacuum Coating

Resistance, laser, and ultrasonic welding

PCBA Assembly

3D printing (FDM, SLA, Polyjet, DMLS)

Top Skills Utilized

Product Design

Mechanical, Thermal, Electrical Simulations

DFMEA

Testing Development

Negotiating

Battery Design

High volume DFM

M18 Forge 12 AH Battery

Assisted in the development of the housing and PCBA for the M18 Forge 12 Ah battery launched in 2024.

Conducted drop simulations using Altair Simlab/Hyperworks and ANSYS LSDYNA to simulate the movement of the housing relative to the PCBA.

Determined potential housing movement and referenced assembly stack ups to establish PCBA component clearance requirements prior to mass production launch.