Milwaukee Tool - Hardware Systems

Milwaukee Tool - Hardware Systems

Shockwave

Shockwave

Role

Lead Industrial Designer

Scope

Core product

Packaging

3D Rendering

3D Printing

Challenge

Milwaukee Tool needed a better driver bit set experience because users struggled to remove smaller bits, avoided the awkward case, and struggled with difficult and wasteful packaging.

Solution

I designed a new bit case, bit holders, and compact packaging so the set was easier to open, use, store, display, and ship.

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Evaluating The Problem

Surveys, user interviews, and product audits confirmed the problem areas before design work began. Competitor products were benchmarked to understand where the existing design fell short against available alternatives.

Experience Layers

Five layers made up the full product system. Each contributed to how the set worked, how it was understood, and how it performed at retail and in the field.

0 1

Modular clips

Made smaller bits easier to remove, organize, and return during use.

0 3

Primary retail packaging

Protected and presented the product clearly at the point of purchase. Concept direction by me, structure executed by the packaging designer.

0 5

3D Visuals

Communicated the product structure, modularity, and packaging system clearly before production.

Communicated the product structure, modularity, and packaging system clearly before production.

0 2

Brand system

Aligned the bit set with the Shockwave product family and made it recognizable as a Milwaukee Tool experience. Handled by graphic designers.

0 4

Secondary reusable packaging

Reduced waste and gave the customer a package that kept serving a purpose after purchase.

Reduced waste and gave the customer a package that kept serving a purpose after purchase.

0 1

Modular clips

Made smaller bits easier to remove, organize, and return during use.

0 2

Brand system

Aligned the bit set with the Shockwave product family and made it recognizable as a Milwaukee Tool experience. Handled by graphic designers.

0 3

Primary retail packaging

Protected and presented the product clearly at the point of purchase. Concept direction by me, structure executed by the packaging designer.

0 4

Secondary reusable packaging

Reduced waste and gave the customer a package that kept serving a purpose after purchase.

0 5

3D Visuals

Communicated the product structure, modularity, and packaging system clearly before production.

Collaborated with:

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Industrial designers

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Graphic designers

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Packaging designers

Experience Ecosystem

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Modular clips

The original clips were why users stopped using the case. I designed magnetic holders to replace the tight grip with a passive hold that released without effort. Bit spacing was widened for larger hands, and upright storage was added as an option for faster visual access. Holders stayed configurable so users could organize by their own preference.

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Retail packaging concept

The plastic clamshell was a major pain point. I developed the direction for a matchbox-style paperboard structure that reduced the spatial footprint, simplified unboxing, and still supported peg displays and retail requirements. The packaging designer refined and executed the structure for production. The graphic team handled hierarchy and brand application on the finished box.

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Complete User Journey

A contractor sees the Shockwave set on the peg. The packaging and visual hierarchy put bit count and type front and center, so the buying decision was fast. The matchbox structure opened cleanly, while the outer sleeve and box went in the recycling. On the job, bits came out with one finger or a gloved hand, and when the bit went back, the magnet caught it. The case stayed in the bag to be reused again.

A contractor sees the Shockwave set on the peg. The packaging and visual hierarchy put bit count and type front and center, so the buying decision was fast. The matchbox structure opened cleanly, while the outer sleeve and box went in the recycling. On the job, bits came out with one finger or a gloved hand, and when the bit went back, the magnet caught it. The case stayed in the bag to be reused again.

Outcome

60% Smaller

Reduced packaging footprint

80% More Kits

Increased kits per shipping box

33% Less Trucks

Reduced trucks needed for transport

The redesign improved how the product worked, how it was sold, and how it moved through distribution. The original issues around access, packaging waste, and usability were addressed, improving how the brand shows up through form and packaging.