Abstract: A method of manufacturing a spindle for a reciprocating saw includes machining a first portion of the spindle and forming a throughbore extending through the first portion via a flow welding process. The flow welding process includes rotating a rod relative to the spindle and inserting the rod into the first portion of the spindle, thereby displacing material from the spindle in a direction away from the rod to form the throughbore and a collar adjacent the throughbore.

Abstract: A power tool including a sensor attachment, a housing, a motor, and a power tool controller. The power tool controller is operable or configured to control power provided to the motor. The sensor attachment is coupled to the power tool's housing and includes a first non-contact sensor and a sensor controller. The sensor controller receives signals from the first non-contact sensor related to distance to a work surface and determines a fastener depth based on the signals from the first non-contact sensor. If the fastener depth is greater than or equal to a desired fastener depth, the sensor controller generates and sends a control signal to the power tool controller. In response, the power tool controller turns off or cuts power to the motor.

Abstract: A fastener driver includes a housing, a cylinder disposed within the housing, a piston positioned and moveable within the cylinder, and a driver blade. The driver blade includes a body defining a first end having an aperture defined therein and a second end opposite the first end. The aperture is sized to receive a fastener to attach the driver blade to the piston. The driver blade is moveable with the piston from a first position toward a second position along a longitudinal axis during a fastener driving operation. A nosepiece at least partially defining a fastener driving track through which fasteners are driven. A total length of the fastener driver as measured between a distal end of the nosepiece and a distal end of the cylinder is less than 11.4 inches (289.6 mm).

Abstract: A fastener driver includes a housing, a cylinder disposed within the housing, a piston positioned and moveable within the cylinder, a driver blade attached to the piston and moveable with the piston from a first position toward a second position during a fastener driving operation, and a nosepiece at least partially defining a fastener driving track through which fasteners are driven by the driver blade. The nosepiece includes a longitudinal guide groove in which a fastener is received, and parallel guide ribs extending from an interior surface of the nosepiece, thereby defining an extension of the guide groove. When the driver blade is in the second position, the driver blade partially overlaps with the guide ribs, thereby allowing a first portion of the fastener to be received in the guide ribs and a lower, second portion of the fastener to be received in the guide groove.

Abstract: A power tool including a sensor attachment, a housing, a motor, and a power tool controller. The power tool controller is operable or configured to control power provided to the motor. The sensor attachment is coupled to the power tool's housing and includes a first non-contact sensor and a sensor controller. The sensor controller receives signals from the first non-contact sensor related to distance to a work surface and determines a fastener depth based on the signals from the first non-contact sensor. If the fastener depth is greater than or equal to a desired fastener depth, the sensor controller generates and sends a control signal to the power tool controller. In response, the power tool controller turns off or cuts power to the motor.

Abstract: A fastener driver includes a housing, a cylinder disposed within the housing, and a piston positioned and moveable within the cylinder. The fastener driver additionally includes a nosepiece at least partially defining a fastener driving track through which fasteners are driven, and a driver blade attached to the piston and moveable with the piston to drive the fasteners through the fastener driving track. The driver blade includes an axial guiding projection for guiding the driver blade within the nosepiece, and wherein the projection terminates before a distal end of the driver blade.

Abstract: A fastener driver includes a housing, a cylinder disposed within the housing, a piston positioned and moveable within the cylinder, and a driver blade. The driver blade includes a body defining a first end having an aperture defined therein and a second end opposite the first end. The aperture is sized to receive a fastener to attach the driver blade to the piston. The driver blade is moveable with the piston from a first position toward a second position along a longitudinal axis during a fastener driving operation. A nosepiece at least partially defining a fastener driving track through which fasteners are driven. A total length of the fastener driver as measured between a distal end of the nosepiece and a distal end of the cylinder is less than 11.4 inches (289.6 mm).

Abstract: A fastener driver includes a housing, a cylinder disposed within the housing, and a piston positioned and moveable within the cylinder. The fastener driver additionally includes a nosepiece at least partially defining a fastener driving track through which fasteners are driven, and a driver blade attached to the piston and moveable with the piston to drive the fasteners through the fastener driving track. The driver blade includes an axial guiding projection for guiding the driver blade within the nosepiece, and wherein the projection terminates before a distal end of the driver blade.

Abstract: A method of manufacturing a spindle for a reciprocating saw includes machining a first portion of the spindle and forming a throughbore extending through the first portion via a flow welding process. The flow welding process includes rotating a rod relative to the spindle and inserting the rod into the first portion of the spindle, thereby displacing material from the spindle in a direction away from the rod to form the throughbore and a collar adjacent the throughbore.

Abstract: A fastener driver includes a housing, a cylinder disposed within the housing, and a piston positioned and moveable within the cylinder. The fastener driver additionally includes a nosepiece at least partially defining a fastener driving track through which fasteners are driven, and a driver blade attached to the piston and moveable with the piston to drive the fasteners through the fastener driving track. The driver blade includes an axial guiding projection for guiding the driver blade within the nosepiece, and wherein the projection terminates before a distal end of the driver blade.

Abstract: A reciprocating saw includes a housing, a motor positioned within the housing, a drive shaft defining a longitudinal axis, and a spindle positioned substantially within the housing and coupled to a wobble plate. The spindle includes a throughbore formed by a flow welding process, wherein the throughbore extends through the spindle to receive the wobble plate.

Abstract: A power tool including a sensor attachment, a housing, a motor, and a power tool controller. The power tool controller is operable or configured to control power provided to the motor. The sensor attachment is coupled to the power tool's housing and includes a first non-contact sensor and a sensor controller. The sensor controller receives signals from the first non-contact sensor related to distance to a work surface and determines a fastener depth based on the signals from the first non-contact sensor. If the fastener depth is greater than or equal to a desired fastener depth, the sensor controller generates and sends a control signal to the power tool controller. In response, the power tool controller turns off or cuts power to the motor.

Abstract: A power tool including a sensor attachment, a housing, a motor, and a power tool controller. The power tool controller is operable or configured to control power provided to the motor. The sensor attachment is coupled to the power tool's housing and includes a first non-contact sensor and a sensor controller. The sensor controller receives signals from the first non-contact sensor related to distance to a work surface and determines a fastener depth based on the signals from the first non-contact sensor. If the fastener depth is greater than or equal to a desired fastener depth, the sensor controller generates and sends a control signal to the power tool controller. In response, the power tool controller turns off or cuts power to the motor.

Abstract: A fastener driver includes a housing, a cylinder disposed within the housing, and a piston positioned and moveable within the cylinder. The fastener driver additionally includes a nosepiece at least partially defining a fastener driving track through which fasteners are driven, and a driver blade attached to the piston and moveable with the piston to drive the fasteners through the fastener driving track. The driver blade includes an axial guiding projection for guiding the driver blade within the nosepiece, and wherein the projection terminates before a distal end of the driver blade.

Abstract: A reciprocating saw includes a housing, a motor positioned within the housing, a drive shaft defining a longitudinal axis, and a spindle positioned substantially within the housing and coupled to a wobble plate. The spindle includes a throughbore formed by a flow welding process, wherein the throughbore extends through the spindle to receive the wobble plate.

Abstract: A power tool including a sensor attachment, a housing, a motor, and a power tool controller. The power tool controller is operable or configured to control power provided to the motor. The sensor attachment is coupled to the power tool's housing and includes a first non-contact sensor and a sensor controller. The sensor controller receives signals from the first non-contact sensor related to distance to a work surface and determines a fastener depth based on the signals from the first non-contact sensor. If the fastener depth is greater than or equal to a desired fastener depth, the sensor controller generates and sends a control signal to the power tool controller. In response, the power tool controller turns off or cuts power to the motor.