Brush Motor vs. Brushless: 5 Data-Backed Factors for Your 2025 Tool Purchase

Abstract

The direct current (DC) brush motor, a foundational technology in electromechanics, maintains a significant and justifiable position in the 2025 landscape of professional and consumer tools, despite the proliferation of brushless alternatives. An examination of its operational principles reveals a design characterized by elegant simplicity, facilitating direct control and robust performance. This analysis evaluates the enduring viability of the brush motor through a comparative framework, assessing it against its brushless counterpart on five pivotal factors: performance characteristics, economic implications including acquisition and long-term ownership costs, maintenance demands and repairability, overall energy efficiency, and its status as a technologically mature and widely available option. While brushless motors offer notable advancements in efficiency and reduced wear, the brush motor presents a compelling case based on its lower initial cost, straightforward maintenance, and high torque output at low speeds. For a substantial range of applications, particularly in corded professional power tools, the brush motor remains not merely a legacy option but a logically and economically sound choice for discerning users.

Key Takeaways

• The simple design of a brush motor often results in a lower initial purchase price for tools.
• Maintenance typically involves replacing inexpensive and accessible carbon brushes.
• Brush motors provide excellent starting torque, which is ideal for many demanding tool applications.
• Choosing the right brush motor tool depends on balancing cost, performance, and maintenance needs.
• Repairability is a key advantage, as users can often perform basic service themselves.
• For many corded tools, the efficiency difference compared to brushless is a negligible factor.

Table of Contents

• Understanding the Brush Motor: A Foundational Technology
• Factor 1: Performance and Application Suitability
• Factor 2: The Economic Equation: Cost of Acquisition and Ownership
• Factor 3: Maintenance, Repairability, and Longevity
• Factor 4: Efficiency and Power Consumption
• Factor 5: Technological Maturity and Market Availability
• Frequently Asked Questions (FAQ)
• Päätelmä
• References

Understanding the Brush Motor: A Foundational Technology

To grasp the arguments for or against a particular technology, one must first cultivate an intimate understanding of its inner life, its fundamental principles of operation. The brush motor is not merely an antiquated piece of machinery; it is a direct and elegant application of electromagnetic theory. At its heart, any electric motor is a device that converts electrical energy into mechanical motion. It achieves this through the interplay of magnetic fields. Imagine holding two magnets; you can feel them either attract or repel each other. A motor harnesses this invisible force, orchestrating it to create continuous rotation.

The brush motor accomplishes this with a design that has been refined for over a century. Let us visualize its core structure as a sort of dynamic sculpture. There are stationary parts and rotating parts, each playing a critical role in a continuous dance of attraction and repulsion.

The Core Principle: How It Works

The stationary part of the motor is the stator. In a common DC brush motor, the stator consists of permanent magnets or field coils that create a constant, stationary magnetic field. This field provides the environment within which the action happens.

The rotating part, known as the rotor or armature, is an assembly of coiled wires wrapped around an iron core. When direct current (DC) electricity flows into these coils, the armature itself becomes an electromagnet. Now we have two magnetic fields: one from the stationary stator and one from the rotating armature. Just like the two magnets you imagined holding, these fields will interact. The north pole of the armature’s electromagnet will be repelled by the stator's north pole and attracted to its south pole, causing the armature to turn.

But how does it keep turning? If the armature's magnetic field remained static, it would simply rotate until its poles aligned with the opposite poles of the stator and then stop, locked in a magnetic embrace. The genius of the brush motor lies in its ability to continuously reverse the polarity of the armature's magnetic field.

Components of a Classic Brush Motor

To understand this continuous reversal, we must look at two other key components: the commutator and the brushes.

• The Commutator: This is a segmented copper ring attached to the armature's axle. Each segment of the commutator is connected to a specific coil on the armature. As the armature spins, the commutator spins with it.
• The Brushes: These are small blocks of a conductive material, typically carbon, that are held in place by springs, ensuring they maintain physical contact with the rotating commutator segments. The DC power from the battery or wall outlet is fed through these brushes to the commutator.

Think of the commutator and brushes as a sophisticated electrical switch. As the armature rotates, the stationary brushes slide from one commutator segment to the next. This action switches the direction of the current flowing into the armature coils. By reversing the current, the magnetic polarity of the armature is flipped. The part of the armature that was just being attracted to the stator's south pole is now repelled by it, and this constant switching—repel, attract, switch, repel, attract, switch—is what produces continuous, fluid rotation. This entire process is known as mechanical commutation.

The Role of Commutation

The act of commutation is the very soul of the brush motor. It is a physical, tangible solution to the problem of sustained rotation. The brushes are the bridge that carries electrical energy from the static power source to the dynamic, spinning world of the armature. The commutator is the gatekeeper, directing that energy to the correct coils at the precise moment to maintain the rotational force, or torque.

This physical contact, however, is also the source of the brush motor's primary limitations. The friction between the brushes and the commutator generates heat, creates electrical sparks (arcing), and, over a great many rotations, causes the carbon brushes to wear down. It is an elegant, yet imperfect, system. Comprehending this trade-off between simple, effective design and inherent mechanical wear is foundational to making an informed decision when selecting professional power tools.

Factor 1: Performance and Application Suitability

When we evaluate a motor for a tool, we are fundamentally asking about its capabilities. How does it behave under load? How precisely can we control it? In which scenarios does it excel? The performance profile of a brush motor offers a distinct set of answers to these questions, answers that make it uniquely suited for certain tasks, even in a world where brushless technology is prevalent.

Torque and Speed Characteristics

One of the most celebrated attributes of a series-wound DC brush motor is its remarkably high starting torque. Torque is the rotational force a motor can produce. Imagine trying to loosen a very tight bolt with a wrench; the initial force required to get it to budge is analogous to starting torque. A brush motor, by its very nature, delivers its maximum torque at zero speed.

This happens because when the rotor is stationary, the current flowing through the armature is at its highest, limited only by the resistance of the windings. This large current creates a very strong magnetic field in the armature, resulting in a powerful turning force against the stator's field. This characteristic is immensely valuable for professional power tools. Consider a drill pressing into a hardwood plank or an angle grinder biting into a steel pipe. These tasks demand a great deal of initial force to start and maintain the cutting or drilling action. The brush motor's ability to provide this "grunt" from a standstill is a significant performance advantage. The speed of a brush motor is also straightforward to control: in its simplest form, the rotational speed is roughly proportional to the input voltage. Reducing the voltage slows the motor down, while increasing it speeds it up. This direct relationship allows for simple and cost-effective variable speed triggers in tools like cordless drills and drivers.

Precision and Control

While brushless motors, with their electronic controllers, can offer more sophisticated control algorithms, the brush motor provides a level of precision that is more than adequate—and sometimes preferable—for many applications. As noted in industry analysis, for certain high-precision machine tools, the stability and predictability of DC brush motor control are highly valued (Kingsdun Tools, 2024). The feedback loop is inherently mechanical and direct.

Think about feathering the trigger of a cordless drill to slowly drive a screw without stripping the head. The response is immediate and intuitive. There is no complex digital processing between your finger's action and the motor's reaction. This directness can feel more connected and tactile to an experienced operator. While brushless motors can achieve incredible stability, they sometimes exhibit less smooth operation at very low speeds, a phenomenon known as "cogging," unless they are paired with advanced sensor systems and controllers, which adds to their cost and complexity (bldcmotor.org, 2025). The brush motor's operation, by contrast, is often smoother at these crawling speeds, making it suitable for tasks requiring delicate control.

When a Brush Motor is the Superior Choice

A rational assessment reveals numerous scenarios where selecting a tool with a brush motor is not a compromise but a strategic choice.

1. High-Torque, Intermittent-Use Applications: For tools that need a lot of power in short bursts, like impact wrenches or heavy-duty hammer drills, the high starting torque of a brush motor is a perfect match.
2. Cost-Sensitive Applications: When equipping a large crew or starting a new business, the lower initial cost of brushed tools allows for the acquisition of more professional power tools for the same capital investment.
3. Simple, Fixed-Speed Tools: For many benchtop tools like grinders, sanders, or some types of saws that run at a constant speed, the complexities and cost of a brushless system offer no tangible benefit. A robust brush motor is a reliable and economical engine for these workhorses.
4. Environments with Simple Repair Needs: In remote job sites or in regions where access to specialized electronic repair services is limited, the mechanical simplicity of a brush motor is a profound advantage. A user can often diagnose and replace worn brushes with basic hand tools, restoring a tool to full function.

Case Study: Corded Drills and Grinders

Let's consider the ubiquitous corded angle grinder, a staple in metal fabrication shops and construction sites worldwide. These tools are subjected to immense and fluctuating loads. The operator might be leaning heavily into the tool for a deep cut one moment and using it for light surface polishing the next. The brush motor inside is perfectly adapted to this abuse. Its high torque helps the grinding disc power through tough material without stalling. Since it is a corded tool, the lower efficiency of the brush motor is of little consequence—there is no battery to drain. Its simple, rugged construction can withstand the vibrations and dust of a harsh working environment. Furthermore, its lower manufacturing cost makes the tool affordable and, in a sense, more disposable in a high-turnover professional environment. A similar logic applies to many corded drills, circular saws, and reciprocating saws, where the virtues of high torque and low cost outweigh the benefits of brushless technology.

Factor 2: The Economic Equation: Cost of Acquisition and Ownership

The decision to purchase a tool is an economic one, balancing immediate expenditure against future value. In the debate between brushed and brushless motors, the financial dimension presents one of the clearest arguments for the continued relevance of the brush motor. The economic analysis extends beyond the price tag on the shelf to encompass the total cost of ownership over the tool's life.

Initial Purchase Price Comparison

The most immediate and compelling financial advantage of a brush motor lies in its lower manufacturing cost, a saving that is consistently passed on to the consumer. The reason for this cost difference is rooted in the design philosophy of the two motor types. A brush motor is a masterpiece of mechanical engineering; its control system is physically built into its structure through the commutator and brushes.

A brushless motor, in contrast, shifts this complexity from the mechanical to the electronic realm. It requires a sophisticated electronic speed controller (ESC) to function. This controller is essentially a small computer with power transistors that must precisely time the delivery of electricity to the stator windings to create the rotating magnetic field. This ESC adds a significant cost in terms of components, design, and manufacturing. The brushless motor itself also uses more expensive high-strength permanent magnets. The collective result is that, for a tool of comparable power and quality, the version with a brush motor will almost always be less expensive to purchase initially (Blikai, 2024).

This price differential is not trivial. For a professional contractor, a home builder, or even a serious hobbyist, the savings can be substantial when purchasing a full suite of tools. Choosing brushed versions of drills, saws, and grinders could free up capital for other essential equipment, such as high-quality attachments or precision measuring tools.

Note: Prices are illustrative estimates for mid-range professional tools and can vary significantly by brand, features, and retailer.

Long-Term Financial Considerations

The economic analysis does not end at the checkout counter. The total cost of ownership includes maintenance and potential repair costs over the tool's lifespan. Here, the picture becomes more nuanced, but the brush motor still holds a strong position.

The primary wear item in a brush motor is, predictably, the brushes. These carbon components are designed to be sacrificial. Over hundreds of hours of use, they wear down and will eventually need to be replaced. However, this is where the economic advantage reappears. A set of replacement brushes for a common professional power tool typically costs only a few dollars. As pointed out by Kingsdun Tools (2024), this low cost of replacement parts makes maintenance extremely affordable.

Furthermore, the replacement process is often simple enough for the user to perform themselves with basic tools, eliminating the cost and downtime associated with sending a tool to a service center. A brushless motor, having no brushes, does not have this maintenance requirement. However, if a brushless motor's electronic controller fails, the repair is often much more expensive, frequently approaching the cost of a new tool. The controller is a sealed electronic unit that is not typically user-serviceable. Therefore, while a brush motor may require more frequent, low-cost maintenance, a brushless motor may face the possibility of a less frequent but catastrophic and high-cost failure. For a user who values predictability and the ability to self-service their equipment, the brush motor's economic model can be very appealing.

Factor 3: Maintenance, Repairability, and Longevity

The lifespan and serviceability of a tool are deeply connected to the user's experience of ownership. A tool that can be easily maintained and repaired is not just an object but a long-term partner in work. The brush motor, with its mechanical nature, presents a distinct paradigm of maintenance and longevity when compared to its electronic brushless counterpart.

The Life and Death of Carbon Brushes

The carbon brushes are the heart of the maintenance story for a brush motor. They are the only components designed for regular wear and replacement. As the motor runs, the brushes are in constant physical contact with the spinning commutator, and this friction slowly grinds the carbon away. Simultaneously, small electrical arcs that occur as the brushes move between commutator segments also contribute to their erosion.

How can one tell when brushes are nearing the end of their life? There are several tell-tale signs. The tool's performance may become erratic, with a noticeable loss of power or inconsistent speed. You might observe excessive sparking visible through the tool's ventilation slots—more than the faint, normal sparking of a healthy motor. A distinct ozone or "burning" smell can also indicate that the brushes are worn out and arcing heavily. Finally, if the brushes wear down completely, the motor will simply stop working as the electrical connection to the armature is lost.

The lifespan of a set of brushes can vary dramatically, from as little as 50 hours to over 200 hours of runtime, depending on the quality of the brush material, the design of the motor, and how hard the tool is used. A tool under constant heavy load will wear through brushes faster than one used for light-duty, intermittent tasks.

DIY Repair and Component Accessibility

Herein lies a significant virtue of the brush motor design: the ease and low cost of this inevitable maintenance. For many professional power tools, the brushes are housed in externally accessible ports. Replacing them can be as simple as unscrewing two plastic caps, pulling out the old spring-loaded brush assembly, inserting a new one, and replacing the cap. The entire process might take less than five minutes and require only a flathead screwdriver.

This accessibility empowers the user. There is no need for a specialized technician or a trip to a service center. A contractor on a job site can carry spare brushes and get a vital tool back in operation with minimal downtime. This level of user-serviceability fosters a sense of self-reliance and control over one's equipment. It stands in stark contrast to many modern electronic devices that are sealed and designed to be replaced rather than repaired. The brush motor, in this sense, belongs to an older, more sustainable philosophy of ownership. It is a system that invites understanding and hands-on maintenance, making tools like powerful blower tools a long-term investment rather than a disposable commodity.

Lifespan Expectations in Professional Settings

What does this mean for the overall lifespan of the tool? A well-maintained brush motor can last for thousands of hours. With regular brush changes, the primary limiting factor becomes wear on the commutator and the motor bearings. The commutator can become scored or uneven over time, but even this can often be remedied by a professional who can skim it on a lathe, restoring a smooth surface. Bearings are also replaceable components.

A brushless motor, free from brush and commutator wear, theoretically has a longer potential lifespan, limited primarily by its bearings. However, this longevity is contingent on the survival of its electronic controller. The ESC is sensitive to voltage spikes, overheating, and physical shock. In the rough-and-tumble environment of a construction site, the failure of this electronic brain is a real possibility. When an ESC fails, the tool is completely inoperable, and the repair is often uneconomical.

Therefore, the longevity question is not straightforward. A brush motor offers a predictable path of gradual wear and simple, affordable maintenance. A brushless motor offers a potentially longer life with no intermediate maintenance, but carries the risk of a sudden, expensive, and often terminal failure. For a professional who values predictability and repairability, the known lifecycle of a brush motor can be more reassuring than the all-or-nothing proposition of a brushless one.

Factor 4: Efficiency and Power Consumption

The concept of efficiency in a motor is a measure of how well it converts electrical energy into useful mechanical work. In an ideal world, 100% of the electricity would become rotational force. In reality, some energy is always lost, primarily as heat. The debate surrounding motor efficiency is particularly salient in the context of cordless tools, where every watt of power is precious.

Energy Loss Through Friction and Heat

The primary source of inefficiency in a brush motor is the very mechanism that makes it work: the physical contact between the brushes and the commutator. This sliding contact creates friction, and friction generates heat. This heat is wasted energy that does not contribute to spinning the tool's chuck or blade. Additionally, the electrical arcing that occurs as the brushes switch between commutator segments also generates heat and represents another form of energy loss.

A brushless motor, by its design, eliminates this source of friction. There are no brushes and no commutator. The commutation is handled electronically, with no moving contacts. This immediately makes the brushless motor more efficient. Less energy is wasted as heat, so more of the power drawn from the battery is converted into mechanical work. Manufacturers often claim that brushless motors are 85-90% efficient, whereas brush motors are typically in the 75-80% range. This difference might seem small, but its effects are noticeable. Because a brushless motor runs cooler, it can be pushed harder for longer periods without overheating. The absence of brush friction also means it can often achieve higher top speeds.

Comparing Battery Life in Cordless Tools

The most tangible benefit of this higher efficiency is realized in cordless professional power tools. A battery contains a finite amount of energy. A more efficient motor will be able to do more work with that same amount of energy. This translates directly to longer runtime per battery charge.

Imagine two identical cordless drills, one with a brush motor and one with a brushless motor, both equipped with the same battery. If both are used to drive 3-inch screws into lumber, the brushless drill will consistently drive more screws before the battery is depleted. This could mean the difference between finishing a task on a single charge or having to stop and swap batteries. For a professional working on a roof or a ladder, where accessing spare batteries is inconvenient, this extended runtime is a significant quality-of-life and productivity improvement. The efficiency of brushless motors is a key reason for their dominance in the premium cordless tool market.

Implications for Corded Professional Power Tools

However, it is crucial to place this efficiency discussion in the proper context. The narrative changes significantly when we shift our focus from cordless to corded tools. A corded angle grinder, circular saw, or router has access to a virtually limitless supply of power from a wall outlet. The 10-15% efficiency difference between a brush motor and a brushless motor becomes almost irrelevant from a power consumption standpoint.

The tool may draw slightly more wattage from the wall to produce the same output power, but the impact on an electricity bill is negligible for all but the largest industrial operations running tools continuously. The heat generation is still a factor—a brushed tool may get warmer during prolonged use—but corded tools are typically larger and incorporate robust fan cooling systems designed to manage this heat effectively.

In this context, the other virtues of the brush motor—its low cost, high starting torque, and simple repairability—come to the forefront. The primary advantage of the brushless design (runtime) is nullified, making the simpler, more economical brush motor an entirely logical and often superior choice for corded applications. The decision-making calculus must always consider the tool's power source. For cordless, efficiency is a paramount concern. For corded, it is often a secondary consideration at best.

Factor 5: Technological Maturity and Market Availability

The age of a technology can be perceived in two ways: as a sign of being outdated or as a testament to its enduring effectiveness. The brush motor, with its origins in the 19th century, falls squarely into the latter category. Its long history has resulted in a level of refinement, reliability, and market ubiquity that new technologies cannot easily replicate.

A Proven and Refined Design

For well over a century, engineers have been designing, building, and improving the DC brush motor. This long process of iterative development has ironed out countless kinks and optimized the design for both performance and manufacturability. The materials used for the magnets, windings, commutators, and brushes have been perfected over generations. Manufacturing processes have been streamlined to produce reliable motors at an incredibly low cost.

This technological maturity means that when you buy a tool with a brush motor from a reputable manufacturer, you are getting a product based on a known and understood quantity. Its performance characteristics are predictable, its failure modes are well-documented, and its construction is based on a proven template. There is a certain security in this. As discussed by commentators on the tool industry, the brush DC motor is a long-standing and widely used technology for good reason (Total Tools, 2022). It represents a stable and reliable solution that has powered industries for decades. This contrasts with newer technologies that, while promising, may still have undiscovered long-term reliability issues or manufacturing inconsistencies.

Breadth of Selection Across Tool Categories

A direct consequence of this maturity and low cost is the sheer breadth of tools that utilize brush motors. They are found in everything from inexpensive cordless screwdrivers to heavy-duty corded demolition hammers. This wide availability gives consumers and professionals an enormous range of choices at every price point. Whether you are a DIY enthusiast looking for a budget-friendly drill for occasional projects or a professional needing a specific type of sander or a powerful cutting tool like a high-performance blower, there is almost certainly a high-quality brushed option available.

This is particularly true in the market for specialized hand tools and attachments. Many niche tools that are produced in lower volumes rely on off-the-shelf, cost-effective brush motors to be economically viable. Developing a custom brushless motor and controller for such a tool would make it prohibitively expensive. The existence of a vast supply chain for generic and semi-custom brush motors enables innovation and variety in the tool market. This choice and availability are a direct benefit to the end-user (GTX Group, 2022).

The Future Trajectory of Motor Technology

Does the rise of brushless technology signal the eventual demise of the brush motor? It seems unlikely. It is more probable that the market will continue to exist in a dual state, with each technology finding its logical place. The comparison is often made to the automotive world: while modern fuel-injected engines are more efficient, simpler carbureted engines still have their place in certain machines and are cherished by enthusiasts for their simplicity and serviceability.

Brushless technology will likely continue to dominate the high-performance, premium cordless tool segment, where its efficiency and power density are key advantages. However, the brush motor will almost certainly retain its stronghold in several key areas:

• Entry-level and Mid-range Cordless Tools: Where cost is a primary driver for consumers.
• Most Corded Tools: Where its lower cost and robust torque are more valuable than marginal gains in efficiency.
• Specialty and Niche Tools: Where the development cost of a brushless system is not justified.
• Applications Valuing User-Serviceability: For users who prefer to maintain their own equipment.

The choice between a brushed and a brushless motor in 2025 is not a choice between an old technology and a new one. It is a choice between two mature, viable technologies, each with a distinct set of trade-offs (ISL Products, 2025). Understanding these trade-offs allows a user to move beyond marketing hype and make a decision based on their specific needs, budget, and philosophy of use.

Frequently Asked Questions (FAQ)

How often do I really need to replace the brushes in my motor?

The replacement interval depends heavily on the tool and how you use it. For a professional using a grinder or circular saw daily under heavy load, you might need to replace brushes every few months, perhaps after 100-150 hours of use. For a homeowner using a drill for occasional projects, the original brushes may last the entire life of the tool. The best practice is to inspect the brushes periodically. Most have a wear line indicating when they should be replaced.

Is a brush motor better for heavy-duty, high-torque tasks?

In many cases, yes. A key characteristic of a DC brush motor is its ability to produce very high torque at low or zero RPM. This is ideal for starting a cut in a tough material or for applications like an impact wrench that require a massive initial twisting force. While high-end brushless motors can also produce high torque, the brush motor delivers it naturally and with a simpler control system.

Can I upgrade my old brushed tool with a brushless motor?

Technically, it might be possible for a highly skilled electrical engineer, but for all practical purposes, the answer is no. A brushless motor requires a complex electronic speed controller (ESC) to function, which a brushed tool does not have. The motor's physical dimensions and mounting points would also be different. The cost and complexity of such a conversion would far exceed the price of simply buying a new brushless tool.

Are brush motors going to become obsolete in 2025?

Not at all. While brushless motors dominate the premium cordless market, the brush motor remains the standard for the vast majority of corded power tools and for more budget-friendly cordless options. Its low cost, simple design, and high torque ensure it will remain a relevant and widely used technology for many years to come.

What are the signs that my tool's brushes are failing?

There are several clear indicators. You may notice a significant loss of power, where the tool struggles with tasks it used to handle easily. The speed might become erratic or inconsistent. You might see excessive, bright blue sparking through the motor vents (some small sparking is normal). A strong smell of ozone or an electrical burning odor is also a common sign. If the tool stops working entirely, worn-out brushes are one of the first and easiest things to check.

Is the dust from carbon brushes harmful?

The dust created from wearing carbon brushes is generally considered a nuisance dust. However, like any fine airborne particulate, it's not ideal to breathe it in. When replacing brushes or cleaning a tool's motor housing, it's a good practice to do so in a well-ventilated area and to wear a simple dust mask to avoid inhaling the fine carbon powder.

Why do some brushed tools create a small spark and a specific smell when new?

This is a normal part of the break-in process. New brushes are perfectly flat, but the commutator is curved. It takes a short period of runtime for the brushes to wear into a shape that perfectly matches the commutator's curve. During this "seating" process, the electrical contact is imperfect, which can cause slightly more arcing (sparking) and a distinct "new motor" smell. This typically subsides after a few minutes of use.

Päätelmä

The inquiry into the relevance of the brush motor in 2025 leads us not to a simple verdict of obsolescence, but to a more nuanced appreciation of its enduring purpose. The narrative that pits "brushed" against "brushless" as a battle between past and future oversimplifies a complex engineering and economic reality. A more discerning perspective frames the two not as rivals, but as distinct solutions to the shared goal of converting electricity into work, each with a unique profile of virtues and compromises.

The brush motor asserts its value through its economic accessibility, its mechanical directness, and its profound repairability. Its lower manufacturing cost democratizes access to professional power tools, enabling more individuals and businesses to acquire the equipment they need. Its high starting torque remains a benchmark for performance in applications that demand raw, immediate power. Perhaps most importantly in an age of sealed electronics, its design harks back to a philosophy of user empowerment, where maintenance is not a specialized service but a straightforward task for the owner.

Conversely, the brushless motor offers a compelling vision of efficiency, longevity, and power density, particularly in the untethered world of cordless tools. For the professional whose productivity hinges on runtime and who operates in demanding conditions, the higher initial investment is often justified.

The rational choice, therefore, is not to declare one technology the victor, but to select the appropriate tool for the task, the budget, and the user's own philosophy of ownership. The brush motor is no relic. It is a proven, robust, and economically sound technology that continues to earn its place in the toolbox through its own distinct merits.

References

Blikai. (2024). Brushed vs brushless motors: What's the difference? (Guide). Blikai. https://www.blikai.com/blog/motors/brushed-vs-brushless-motors-what-s-the-difference-guide

bldcmotor.org. (2025). Brushed DC motor vs. brushless DC motor. ATO. https://www.bldcmotor.org/brushed-dc-motor-vs.-brushless-dc-motor.html

GTX Group. (2022, July 8). Tools with brush and brushless motors – which one to go for?. GTX Group. https://www.gtx-group.com/en/2022/07/08/tools-with-brush-and-brushless-motors-which-one-to-go-for/

ISL Products. (2025). Brushless vs brushed DC motors: Key decision factors. ISL Products International.

Kingsdun Tools. (2024, August 28). Working principle and difference of brushed motor and brushless motor in electric screwdriver. Kingsdun. https://www.kingsduntools.com/Industry-News/Motor-Electric-Screwdriver.html

Total Tools. (2022, December 12). Brushless vs brushed tools. Total Tools. https://www.totaltools.com.au/blog/post/brushless-vs-brushed-motors