MRO Magazine

How Heavy-Duty Tools are Different

Milwaukee Electric Tool makes only heavy-duty tools, designed for professionals, their harsh work environment and their performance requirements. Company engineers design new products through extensive research, focus groups and jobsite visits. By...


November 1, 2004
By MRO Magazine

Milwaukee Electric Tool makes only heavy-duty tools, designed for professionals, their harsh work environment and their performance requirements. Company engineers design new products through extensive research, focus groups and jobsite visits. By understanding the needs of the professional tool user, the engineers develop long-lasting tools that help customers complete their projects fast and safely.

From the cord to the motor windings, there are many features that make Milwaukee tools heavy duty. Eight-foot or longer cords made of synthetic rubber stay flexible in cold weather. The cord protector is a separate component that allows easy cord replacement. Switches are designed to withstand several hundred hours of use. Heavy-duty tools used in extremely dusty conditions also have sealed switches to keep dust out.

Professional tools have twice as many copper bars in the commutator as consumer tools, which makes it possible to wind two independent coils in each lamination slot, giving the tool more power and greater burnout resistance. Motor brushes are precisely positioned, minimizing arcing, which kills motors over time. The motor shaft and the drive mechanism in heavy-duty tools must maintain the correct distance and withstand severe forces from use.

The ball bearings and roller bearings in these tools can control play to ten-thousandths of an inch (0.0001 in.). Designed to hold up under tremendous forces, the wrought steel gears are heat-treated and machined to exacting specifications. The tough polymers used to make the housings resist the effects of grease and solvents and help protect the user from heat and electrical shorts.

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