M18 5" RO Sander

The Milwaukee FUEL M18 5" Random Orbital Sander is a cordless power tool developed to address documented ergonomic and usability issues in a previous-generation product. The project focused on improving balance, grip comfort, and overall user experience while maintaining compatibility with the M18 battery platform. I joined the project at kickoff as an industrial design co-op and co-led design development. Working from prior design research outlining user pain points, I explored alternative battery configurations that helped guide the product architecture toward a more ergonomic and balanced result. My contributions included developing the pommel grip through successive clay iterations, 3D-printed prototypes, and use testing. I applied Milwaukee Tool’s visual brand language to the exterior in accordance with design guidelines and worked closely with engineers and Class-A CAD modelers to integrate internal components, accounting for wall thickness, draft, venting, boss placement, and over-mold requirements. In collaboration with a cross-functional team spanning industrial design, mechanical and electrical engineering, quality, product, and marketing, I owned key design milestones that closely informed the final product, which has since been released to the public with positive reception.