Power tool having stamped brake resistor

A method of stacking a brake resistor assembly of a power tool, the method comprising:

• providing a stamped brake resistor, the stamped brake resistor including a terminal portion and a resistive portion, wherein the resistive portion includes a planar serpentine path forming a plurality of leaves and a gap between each leaf, the resistive portion further including a first leg, a second leg perpendicular to the first leg, a third leg, and a fourth leg perpendicular to the third leg;
• providing a first insulating pad, a second insulating pad, a first heat sink, a second heat sink, and a plurality of fasteners, wherein each of the stamped brake resistor, the first insulating pad, the second insulating pad, the first heat sink, and the second heat sink, includes a plurality of holes;
• aligning, by stacking the first insulating pad, the second insulating pad, the first heat sink, and the second heat sink, the plurality of holes to form a plurality of passages;
• and
• securing, by passing a fastener of the plurality of fasteners through a passage of the plurality of passages, the stamped brake resistor, the first insulating pad, the second insulating pad, the first heat sink, and the second heat sink together.

A braking system for a power tool, the braking system comprising:

• a stamped brake resistor having a terminal portion and a resistive portion, the resistive portion including a planar serpentine path forming a plurality of leaves and a gap between each leaf, the resistive portion further including a first leg, a second leg perpendicular to the first leg, a third leg, and a fourth leg perpendicular to the third leg;
• a first insulating pad and a second insulating pad that sandwich the stamped brake resistor;
• and
• a controller including an electronic processor and a memory, the controller connected to a motor and a brake switch, the controller configured to:
• control power delivered to the motor based on a position of a trigger,
• determine to brake the motor during operation of the motor, and
• activate, in response to determining to brake the motor, the brake switch to connect the stamped brake resistor to the motor.