DeWalt 20V MAX XR POWERSTACK 5Ah Battery (2 Pack)

Why I switched to the PowerStack 5Ah pack

I’ve been running DEWALT’s standard 5.0Ah XR packs for years, so a change to the PowerStack 5Ah pack wasn’t about chasing specs—it was about seeing whether the pouch-cell design actually changes how the tools feel under load. I spent several weeks rotating a pair of these packs through impact drivers, a compact drill, a die grinder, a 6-1/2" circular saw, and an axial blower. The takeaway: they don’t reinvent runtime, but they do change how certain tools behave in a way I appreciate.

Design and build

The PowerStack 5Ah pack trades cylindrical cells for pouch cells, which lets DEWALT keep capacity at 5.0Ah while lowering the profile. The pack measures roughly 2.2 inches tall and comes in at about 1.5 pounds—right in the same ballpark as the familiar XR 5Ah, but it feels denser and more planted on tools.

The overmolded rubber base is a meaningful upgrade. It’s non-marring and has enough friction to keep a drill standing upright on smooth surfaces. I set these down on painted cabinetry and finished countertops with no scuffs, and the base seems to absorb small bumps and knocks better than hard plastic. The 3-LED fuel gauge is basic but readable; no learning curve, just tap and go.

Fitment was a non-issue on every 20V MAX tool and charger I tried. The pack slides straight in and positively clicks home on classics like the DCD791 drill, compact impacts, and even bulkier tools like a grinder and blower. If your tool collection already rides on DEWALT’s 20V MAX rail, you’re good.

Ergonomics and balance

On compact drills and impact drivers, the lower profile is legitimately helpful. The tool sits closer to your hand, which improves balance and makes overhead or tight-space work a little less fatiguing. Under shelves and inside cabinets, the shorter height keeps the battery from bumping into the work. On larger tools like a grinder or circular saw, the benefit is less about size and more about stability—the battery’s footprint and rubber base give the tool a solid stance when you set it down.

Weight is essentially a wash with the traditional 5Ah XR pack. If you’re coming from 2.0Ah or 4.0Ah compacts, you’ll feel the extra heft, but if 5Ah is your normal, this doesn’t feel heavier in the hand.

Power under load

DEWALT claims a significant power increase over older 5Ah packs. Manufacturer claims are one thing; what I pay attention to is voltage sag and how the tool behaves when you lean on it. In high-draw applications, the PowerStack 5Ah does feel stronger.

• Circular saw: Ripping 2x material, the saw held speed better. The cut tone stayed steadier and I could push a touch harder without triggering a bog.
• Die grinder and angle grinder: Grinding and cutting are where I noticed the biggest difference. The pack seemed to deliver current more willingly, keeping the tool in its sweet spot longer before thermal cutback.
• Blower: On high, there’s a small but noticeable improvement in initial punch. It’s not night-and-day, but startup feels snappier.

On drills and impact drivers doing general fastening, the difference is minor. You may catch a crisper surge on big lags or a hole saw start, but in day-to-day carpentry and cabinet work, both packs finish the job just fine. If your kit skews toward saws, grinders, and blowers, the PowerStack advantage is more apparent.

Runtime and charging

Capacity is still 5.0Ah, so baseline runtime is comparable to a standard XR 5Ah under moderate loads. In heavy, continuous tasks (grinding, ripping), I saw a modest improvement—likely due to reduced sag and heat—but it’s not a leap. Expect similar overall runtime with slightly better stamina when you’re pushing hard.

Charge times on a mainstream DEWALT charger were right around an hour and a half from a low state of charge. The 3-LED gauge is simple, but I appreciate being able to check status at a glance when rotating packs mid-task.

Heat management and durability

Pouch cells spread heat differently than cylindrical cells, and in practice, the pack surfaces warmed evenly without hot spots. After long cuts and grinding sessions, the packs were warm but not alarmingly so, and cooldown times felt normal. I never hit a thermal shutdown in regular use.

I’m a fan of the rubber base. Aside from protecting surfaces, it dampens small drops. I intentionally set the tool down a bit harder than I should and brushed the pack against metal edges—a typical day in a shop—and there’s only minor cosmetic wear. The internal structure feels rigid; no creaks or flex when squeezing the housing.

Compatibility considerations

Everything in the 20V MAX line I own accepted the pack, and chargers recognized it immediately. On a couple of tools, the slightly wider footprint makes for a stable base when standing upright, and the lower height helped with clearance in awkward corners. If you use tight holsters or fitted belt pouches designed around older compact packs, check the fit—the base texture can add friction when sliding in and out.

Long-term claims

DEWALT touts improved cycle life with the pouch stack. I can’t verify that yet. What I can say is that after frequent cycling and regular top-offs, both packs hold charge predictably, the fuel gauges remain consistent, and performance hasn’t tapered. As with any lithium-ion pack, avoiding deep, hot storage and charging in a reasonable temperature range will help longevity. Register the packs for warranty coverage (3-year limited, 1-year free service); it’s worth the minute it takes.

Value and who benefits

This is the hard part. The PowerStack 5Ah pack is priced at a premium. Street pricing fluctuates, and sales do happen, but you’ll generally pay more than a two-pack of standard XR 5Ah batteries. Whether it’s worth it depends on your workload:

• Strong fit: Trades that lean on grinders, circular saws, and high-draw tools; mechanics using impact wrenches and die grinders; anyone who values the lower profile and more planted feel on compact drivers and drills.
• Good but optional: General carpentry, maintenance, and punch-list work where tools rarely see prolonged high-load use. The standard XR 5Ah remains a very good value here.
• Budget-conscious setups: If price-per-amp-hour is your top priority and you aren’t pushing tools hard, you’ll get better value from conventional packs.

Small usability touches

• The base’s non-marring rubber matters more than I expected. It’s nice to park a driver on a finished surface without grabbing a rag first.
• The lower height quietly improves balance on compact tools. That reduces wrist fatigue over a day of overhead work.
• The fuel gauge is basic but reliable. I’d still love a four-bar or percentage-style readout in the future.

What I’d change

• Cost is the barrier. A more aggressive two-pack price—or bundling with a fast charger—would make this an easier yes.
• A higher-resolution fuel gauge would better match the “premium” positioning.
• I’d like to see an official, detailed thermal and cycle-life spec sheet. The tech is promising; the data would back it up.

Recommendation

I recommend the PowerStack 5Ah pack for users who regularly push high-draw tools and for anyone who values improved balance and a non-marring, stable base. In heavy applications, the pack’s steadier power delivery keeps tools at speed longer, and the low profile makes compact drivers and drills feel better in hand. If your work is mostly light to moderate and you’re watching the budget, the standard 5Ah XR remains the smarter buy—you won’t give up much runtime, and the performance gap is small on everyday tasks. But if you live in grinders, saws, or high-demand outdoor tools, or you want the nicest-feeling 5Ah option in DEWALT’s 20V MAX ecosystem, this pack earns its spot—especially when you catch it on sale.