A far cry from manual labour, modern hand-held tools powered by electricity or pneumatic pressure execute work with speed, accuracy and consistency hitherto unheard of. Dhananjay Sardeshpande delves into the range of tools that have revolutionised furniture manufacturing…

High precision and consistency are required especially in sanding and buffing.

A power tool is actuated by an additional power source and mechanism other than solely manual labour. They can be powered by electrically driven motors or fed by pneumatic pressure.

Power tools are used in a wide range of industries and construction applications – from metal, glass, stone, plastic and ceramic cutting and grinding to drywall construction.

Power tools are acknowledged for their speed (50x), efficiency (30x) and accuracy (80x) at work, besides ease of assembling and handling. They can be further classified as stationary or portable. While portable power tools have obvious advantages in mobility, stationary power tools have advantages in speed and precision.

For example, a table saw not only cuts faster than a regular hand saw, but the cuts are smoother, straighter and more square than what is normally achievable with a hand-held power saw. Stationary power tools – such as lathes – can produce objects that cannot be made in any other way (round objects).

Until the 1040s power tools were usually housed in cast metal housings that were heavy and caused repetitive use injuries, and often shocking the user. Then came housings of thermos-setting polymer plastics, and later fibreglass.

Work enablers

While the scope of power tools today is nearly infinite, let us focus on those that find applications in woodworking. Without assistance from hand-held power tools (we are not talking wood processing machinery here) can you imagine delivering 100 kitchens a month to a housing project?

Or a bigger volume of doors and door frames to a real estate developer? Fit out a retail space in a record couple of days? Or manage to meet timelines for seating and desking for a large office project?

Or deliver tables and chairs in large volumes – even bespoke upholstered furniture pieces – for home, hospitality, entertainment or institutional projects?

These scenarios are possible only because of the speed, efficiency and accuracy of power tools at work, during production in the workshop and assembling furniture on-site.

In furniture manufacturing, these tools greatly contribute to the following functions: cutting and sizing of lumber and panels; drilling and routing; shaping and carving; joining and fastening; bolting and stapling; sanding, coating and painting; sewing and stitching (upholstery) – even grinding and sharpening saw blades and tool bits.

Battery boon

Lithium-ion batteries have replaced conventional nickel-cadmium (Ni-Cd) and nickel-metal hydride (Ni-MH) power sources in these tools. Lithium-ion batteries deliver higher energy density and extended operational life while being lightweight and exhibiting minimal self-discharge.

Ongoing advancements in battery technology contribute to the growing popularity of cordless power tools, featuring high-density batteries that offer longer operational durations once charged.

Voltage is one of the most important factors for battery compatibility. The higher the voltage rating on the tool, the more power that tool can deliver. Using a battery with the wrong voltage rating may cause damage to the tool and the user. Since 2021, 18-Volt battery packs have been the standard in new power tools.

The Ampere-hour rating indicates how long the power tool can operate before it needs to be recharged. If comparing two batteries with the same battery technology and same voltage rating, a battery with twice the Amp hour rating should last about twice as long. Batteries with a higher Amp hour rating can also let the power tool deliver a slightly higher peak power.

But not all battery powered power tools use batteries that are compatible across brands and models. This may cause vendor lock-in and result in poor sustainability if the battery, charger, or power tool component fails, calling for replacements.

Even when using the same battery technology, voltage rating and Amp hour rating, the interface of batteries for power tools is not always compatible across different manufacturers. To solve this there are after-market adapters so that the user can mix and match batteries between well-known brands. Needless to say these cannot fully implement the tool’s battery safety and monitoring systems.

Power tools have revolutionised cutting and sizing, drilling and routing, joining and fastening, sanding, coating and painting, sewing and stitching.

Health risks

Hand-held power tools produce large amounts of noise, vibrations and emissions, including ultra-fine particles. Particulates are among the most harmful form of air pollution as they can penetrate deep into the lungs and brain from the blood stream, causing health problems. High dust levels are caused by:

• Equipment using high energy, especially cut-off saws, grinders and grit blasters

• Work method, where dry sweeping can create a lot of dust when compared to vacuuming or wet brushing

• Work area: the smaller the enclosed a space, the more dust will build up

• Time: the longer you work the more dust there will be

Examples of high dust level tasks include using power tools to cut, grind, drill or prepare a surface, dry sweeping, or sanding taped plasterboard joints. Especially in woodworking, manufacturers are now making power tools equipped with dust collection systems.

Hearing loss is another health concern as using power tools without hearing protection over a long period of time can put the user at risk for hearing loss. The National Institute for Occupational Safety and Health in the US recommends that workers should not be exposed to noise at 85 dB or above.

Most power tools, including drills, circular saws, belt sanders and chainsaws, operate at sound levels above this limit, some even reaching over 100 dB. It is strongly recommended that users wear hearing protection while using these kinds of power tools.

Recent developments

In February 2024, Robert Bosch GmbH introduced the new AdvancedDrill and AdvancedImpact 18V-80 QuickSnap, enabling powerful screwing and drilling even in tight spots. These cordless tools are part of Bosch’s 18-V ‘Power for All System’ covering more than 70 tools and appliances.

In February 2024, Makita USA Inc. launched the 5-inch paddle switch angle grinder with AC/DC switch, providing another choice for professionals in metal fabrication shops, as well as the electrical, mechanical and plumbing trades.

In October 2023, Milwaukee, a subsidiary of Techtronic Industries Co. Ltd., introduced the innovative M18 Fuel 5-inch dual-trigger braking grinder, offering dual-trigger activation, a fixed side handle, and ‘auto-stop’ kickback control for enhanced user control and safety on the worksite.

In August 2023, Dewalt, a Stanley Black & Decker brand, introduced the new 20V Max XR brushless cordless ½-inch high torque impact wrench (DCF961), the industry’s top-rated cordless 1/2 in. impact wrench.

The global market for power tools in 2024 was reported to be US$ 39.5 billion, according to a recent report put out by Markets & Markets. It estimates the market to grow to US$ 45.5 billion by 2029, with a compound annual growth rate of 2.9%. This will be primarily led by the Asia-Pacific region, with China, Japan, India and South Korea leading the growth.

Increased adoption of battery-powered power tools globally and the growing construction industry in emerging economies are some of the factors driving the power tools market.

From Industrial Revolution-era factories that employed tools driven by belts from overhead shafts to electric motors and high-performance batteries, power tools have come a long way indeed, changing the nature, scope and speed of woodworking as we know it today!

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