Next semester I am taking a class called Product Engineering and Manufacturing. It's a one semester course where we work with Dewalt tools. Luckily, we have the same tool as last semester, a cordless impact driver. We have to go through the process of finding something to fix on the impact driver, and actually make the improvement on the tool. We will have access to a rapid prototyping machine to make parts. We will sign a NDA with Dewalt at the start of the class, so I dont know how much specific details I will and will not be able to share once the class starts. So basically, I'm looking for any ideas anyone has. We will have to bench test the impact driver and compare it to leading brands. Then there is a whole bunch of other crap we gotta do as well. Some stuff like cost analysis, statistical analysis, bla bla bla. Here is a picture of the impact driver. This is what people did last semester: redesign the case (got it to work) change the cooling fan geometry (did not work) tried to reduce vibration (could not get it to work) added a battery meter indicator (I think it worked, not sure) So, any idearzzz? Edit: Obviously, Dewalt they will give us impact drivers to modify. At the final presentation, Dewalt will come in an evaluate/grade our project.