Behind the Build: Designing the M12 FUEL™ Bandfile Insert
Welcome back to Inside the Lab, where we break down how our design team at Code Breaker Labs turns a simple idea into a job-site-ready insert.
Today, we’re looking at one of our most requested Milwaukee tools inserts — the M12 FUEL™ Bandfile insert we designed to finally make it Milwaukee PACKOUT™-friendly. This insert wasn’t just “shape a pocket and call it a day.” It took research, real-world tool handling, and a whole bunch of prototypes to get right.
Here’s how the design came together.
Design Philosophy: Built for Real Use, Not Just Storage
The Bandfile sees heavy use across carpentry, metalwork, shopfitting, and maintenance — meaning our insert needed to do two things:
- Store everything properly
- Make the tool quicker and easier to use on site
That balance shaped every decision — footprint, angles, ergonomics, storage layout, and even how dust clears out during use. Like all our Milwaukee PACKOUT™ inserts, this one was built around how tradies actually work, not just how things look on a shelf.
Ergonomic Insert Layout
A layout shaped around the way tradies actually grab the tool
From day one, the goal was simple: make the insert feel natural to use — battery on or off.
The Bandfile sits in a contoured pocket with space around the handle so you can grab it without fighting the organiser walls. The user can choose to store the tool with the battery attached or removed, depending on how they prefer to pack out their kit.
The pickup scoop under the grip lets you lift the tool with one hand, even with gloves on — a small detail that makes a big difference when you’re moving fast on site.
Sanding Belt Storage System
A removable holder that adapts to the job
One of the biggest headaches with Bandfiles? Where the hell do you put the belts.
To solve that, we built a belt holder that:
- Comes in 13" and 10" variants
- Stores up to 7 belts
- Uses a bevelled top edge so belts slide on easily
- Can be lifted out and taken to the task
- Includes an integrated allen key compartment
To load it, you simply place one end of the sanding belt over the base of the holder, then use the bevelled top edge to slide the rest of the belt over and down for a snug, repeatable fit. No more crushed belts rolling around the bottom of your PACKOUT organiser.
Extra Battery Storage
Because sanding always needs backup power
Anyone who has used the Bandfile knows it’s a battery muncher.
To keep you running longer, the insert includes a pocket for an extra M12 2.0Ah battery in the top-left corner. It’s out of the way, easy to grab, and keeps your workflow tight — especially for tradies here in Australia running full Milwaukee PACKOUT™ setups.
Integrated Grate System
Keeping your organiser and tools in better condition for longer
Sanding means dust — and lots of it.
To combat that, we integrated a grate system under the sanding belt area. As you use the tool, dust falls through the gaps instead of building up around the belts and tool head. This keeps the organiser cleaner, protects the insert over time, and reduces the grit that usually ends up everywhere.
We also added a pickup cavity at the base so you can easily lift the grate out for cleaning and tip the dust away. Less mess, more work done.
Photos from the Build
Final Thoughts from the Design Team
This insert is built for tradies who rely on the Bandfile as a daily tool — not a once-a-month dust collector. Every pocket, bevel, clearance, and cavity was shaped through hands-on testing and real-world feedback.
Like the rest of our Milwaukee inserts collection, the aim was simple: create a PACKOUT-ready system that actually improves how you use the tool, not just where you store it.
If you’re running other M12 gear as well, you can pair this setup with our dedicated M12 PACKOUT insert for ratchet and sockets to keep more of your compact tools organised in one stack.
The final result? A Bandfile insert that finally does the tool justice — and earns its spot in your PACKOUT tower.