Stanley Black & Decker
Senior Product Design Engineer
The Role
From concept
to production line.
As a Senior Product Design Engineer at Stanley Black & Decker, I drove the mechanical and electromechanical design of consumer products across multiple categories — cordless power tools, high-voltage battery packs, LED lighting systems, audio devices, and jobsite equipment.
My work spanned the complete product lifecycle: requirements definition, concept development, detailed CAD design, DFM/DFA reviews, prototype builds, functional and reliability testing, regulatory compliance coordination, and production handoff.
I worked in a cross-functional environment — partnering with industrial designers, electrical engineers, supply chain, and manufacturing partners — to bring products to market on time and on budget.
Projects
What I Built at SBD
01 · DeWALT Powershift
Served as a core engineer for the DeWALT Powershift 10Ah battery program — a high-impact cordless platform designed for heavy construction tools including rammers, plate compactors, and vibrators.
My responsibilities centered on electromechanical design: PCB modifications, cell-level analysis, and comprehensive safety, reliability, and performance testing across the full voltage range.
02 · Job Site Blower Optimization
Led the design of a next-generation job site blower from brainstorming through production. The redesign simultaneously reduced power consumption by 75% and doubled output performance — results that also translated to $200,000+ in annual manufacturing savings.
- CFD simulations to optimize axial fan geometry and airflow efficiency
- Tolerance stack-up analysis across critical airpath interfaces
- Structural analysis to ensure housing integrity under jobsite conditions
- Full project ownership from concept through production handoff
03 · Redesigned Track Saw Guide
The market-leading aluminum track saw guide was prone to damage during shipping and use. I redesigned the track to enhance durability without sacrificing precision — cutting shipping and warranty costs by 30%.
- Improved structural integrity across the full track length
- Redefined manufacturing approach to reduce tolerance buildup
- Extensive tolerance analysis and FEA to validate performance
- Reliability testing to meet demanding durability targets
04 · Audio System Components — Woofer Spider & Port Design
As part of the speaker design team, I applied FEA to optimize the woofer spider's deformation behavior — balancing compliance for sound quality with fatigue life for longevity.
I also ran CFD simulations on speaker port geometry to enhance acoustic efficiency by analyzing airflow dynamics and pressure gradients through the port at operating frequencies.
05 · LED Light Pipe Design
Contributed to the mechanical design of an audio system's LED light pipe to ensure optimal illumination output and visual uniformity across the product face.
- Ray tracing analysis in TRACE-PRO to evaluate light output (lux) distribution
- Multiple design iterations to perfect light uniformity and coverage
- Simulation-driven optimization before any tooling commitment
06 · Other Projects
Beyond the primary programs above, I designed a new housing for a grinder product line and conducted extensive performance and reliability testing across a wide range of DEWALT tools.
Testing covered drills, impact drivers, angle grinders, circular saws, and reciprocating saws — evaluating performance under load, thermal behavior, drop/vibration durability, and regulatory compliance.
Tools & Skills Applied