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In this post I’ll show you how Dewalt used to build select cordless drills in the USA.
10 years ago Dewalt held one of their last new tool media events inside a distribution center that was partially converted into a cordless power tool assembly facility.
On one side they were assembling 18V cordless power tools, and on the other select 20V Max brushless tools, such as their 3-speed premium hammer drill.
In the middle, aside from the tool demonstrations setup for the media event, they had a couple of stations where brushless motors were being wound and balanced.
Part of the media event involved a “build your own Dewalt drill” interactive experience where we had a hand in assembling our own DCD995 20V Max XR brushless hammer drill.
Step 1: Grab Some Parts
None of the parts that went into the cordless drill were made on-site; all of the components and subassemblies were imported from US and overseas factories.
This is the brushless motor for the XR cordless hammer drill, and it arrived assembled like this.
This is the electronics package. All of the white space-filling plastic is potting, and it serves to protect the electronics and power components from physical shock and vibrations.
Step 2: Connect the Drill Electronics Together
The brushless motor and switch assembly are connected together.
There’s a fixturing jig for that.
The power wires were soldered to the motor, and data communications are done via quick connector.
A single (sensor?) component received heat shrink tubing.
Step 3: Assemble the Drill Housing
Once the main internals have been assembled, it’s time to attach the shell.
The two halves of the cordless drill housing are made elsewhere and shipped together.
A plastic jig holds half of the drill housing in place, and the top piece travels with it on a lower shelf.
This is where the gear box, torque clutch, and drill chuck assembly is added in.
The motor and electronics assembly is then added.
If you look closely, you can see metal pins that have been added to the housing. These presumably help with alignment.
Here’s what everything should look like once everything is assembled. It’s important to keep track of wire positions, not only to make sure everything is where they should be, but to avoid anything getting pinched when the two sides of the drill housing are fastened together.
Everything settles into place.
Torque screwdrivers are used to fasten the two halves of the drill together. The gearbox is also secured to the housing, and here you can see how the assembly jig allows for proper positioning of the parts.
Finishing the drill assembly involved 4 screws placed in the side, 4 screws placed in the front through the gearbox assembly, and then 4 more screws placed in the side. All of the fasteners are installed in a specific order to ensure uniform tightness and consistency.
Step 4: Programming and Testing the Drills
This is where the assembled drills are programmed.
It’s a pretty neat contraption. The drills are programmed through the battery connection, which I never would have guessed.
Here’s the testing station where basic functionality and operated parameters are checked.
There are finger-detecting interlocks and pneumatically-activated drop-down plastic shields.
This station tests various functions, such as the drill’s speed, power draw, LED operation, and thermal shut-off thermistor.
It wasn’t clear to me whether every drill was tested at both stations, or if this station was for spot checks.
Step 5: Kitting and Labeling
After labels are applied, they’re checked by a computer for proper placement. This is also the point at which each drill is given a date code. There are also markings added to the inside of the battery connector housing to show that the drill has passed quality control testing.
Each drill in this line was then kitted with a side handle, charger, batteries, and carrying case, which received a matching serial number.
And that’s how the Dewalt 20V Max XR series cordless hammer drill was built in the USA.
This was all 10 years ago. I’m not sure if Dewalt still assembles any of their cordless power tools in the USA.
Still, I thought you’d enjoy a look at what they at least used to do. Seeing the process was a wonderful experience that I enjoying revisiting.
Bonus: Brushed Motor Drill Assembly
Dewalt was also assembling brushed motor cordless drills at the same facility.
I found it interesting that the drills went through a different assembly process.
Read Also: How Dewalt Brushless Drills are Built in the USA, and More from my Factory Tour
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