The latest advancement in power tools is brushless motors. To understand what brushless motors are, the technology behind them and their benefits, let’s take a look at the existing technology of brushed motors of how they advanced..



How Brushed Motors Work

In a typical electric motor, permanent magnets (stator) sit on the outside and a spinning armature (rotor) resides on the inside. The rotor contains an electromagnet. When electricity passes through the electromagnet, it creates a magnetic field inside the rotor that attracts and repels permanent magnets in the stator.

Brushed Motor
Image Credit: Canva

For a motor to spin 360 degrees, a change in the electromagnet’s polarity must be created. A pair of brushes help with that.

Motor brushes aren’t really brushes. Instead, they’re small blocks of carbon connected to a compression spring. The brushes press against spinning electrodes attached to the rotor. As the electromagnet rotates, the brushes change the magnetic polarity.

Brushed motors are reliable, relatively efficient, and inexpensive to make, but they have distinct limitations. Among them:

  • Carbon brushes wear out and eventually require replacement.
  • As the motor runs, the brushes constantly break and then make electrical contact. That produces sparking and noise.
  • Friction from the brushes rubbing the spinning rotor creates heat, making the motor run hot.
  • Brushes limit the motor’s ultimate top speed.

For these reasons, major tool manufacturers turned to brushless motors for their lines of portable power tools.


Key Differences Between Brushed and Brushless Motors

In a brushless motor, there are no brushes, and the motor’s construction is a bit opposite from that of brushed motors. Permanent magnets move to the rotor while electromagnets connect to the stator.

Then, instead of brushes, a computer connected to high-power transistors charges the electromagnets as the motor turns.

Among the many advantages a brushless motor has over brushed motors include:

  • There are no brushes that wear out or require replacement.
  • The motor runs quieter and cooler without friction and sparking.
  • Runtime for cordless tools increases up to 50%.
  • Precise torque delivery matches the job’s needs.

For example, the motor can sense whether it’s drilling a ¼-inch hole in drywall or a 2-inch hole in steel. It then delivers the right amount of power. Brushed motors run at full speed regardless of torque conditions and requirements.

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While brushless motors have a higher initial cost, long-term savings often outweigh the initial price difference. Greater efficiency means a 50% longer battery charge, you don’t need to replace any brushes during the tool’s life, and you can potentially reuse the motors in future tools. 

As costs decline over time, the payback period on financial investment shortens.


Brushless Motor Use Cases

Five examples of the most popular power tools now incorporating brushless motor technology:

Higher speeds, 50% longer runtime vs brushed motors

Better at maintaining speed and torque under load than brushed motors

Lower vibration, higher stroke rate

Faster disc startup time, lasts longer under strain

Improved torque control and speed

In general, performance gains are most noticeable in tools undergoing frequent starts and stops or highly variable loads during use.


So, Is Brushless Motor Technology Worth It?

For serious DIYers and professional contractors who use power tools daily, investing in brushless models is worth the initial higher cost. They will complete jobs faster with less fatigue, have longer runtime per battery charge, and avoid downtime for maintenance and repairs.

Weekend warriors may be fine with brushed motors if budget is a concern. They may upgrade for major efficiency and capability improvements that brushless tools provide.


FAQs About Brushless Motors

How can I tell if a tool has a brushless motor?

Brushless tools have “brushless” or “BL” in the model name/description. Brushless motors also have electronic circuit boards attached.


Do brushless tools require less maintenance?

Brushless tools need less maintenance because without brushes wearing over time, there’s no need to service and replace components. Brushless tools have fewer mechanical parts overall.


Are replacement parts harder to find?

Sourcing replacement parts for brushless tools can be tricky because of proprietary electronics in the motors. But as manufacturers design motors for longevity, you shouldn’t need replacements as often.


Can I use a brushless tool without power on a job site?

You can use cordless brushless tools without direct power because they hold charges for a long time, but eventually, they must be recharged. Consider backup batteries or a generator for off-grid use. Corded brushless tools can run without battery limitations.


Editorial Contributors
avatar for Jonathon Jachura

Jonathon Jachura

Contributor

Jonathon Jachura is a two-time homeowner with hands-on experience with HVAC, gutters, plumbing, lawn care, pest control, and other aspects of owning a home. He is passionate about home maintenance and finding the best services. His main goal is to educate others with crisp, concise descriptions that any homeowner can use. Jon uses his strong technical background to create engaging, easy-to-read, and informative guides. He does most of his home and lawn projects himself but hires professional companies for the “big things.” He knows what goes into finding the best service providers and contractors. Jon studied mechanical engineering at Purdue University in Indiana and worked in the HVAC industry for 12 years. Between his various home improvement projects, he enjoys the outdoors, a good cup of coffee, and spending time with his family.

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Sabrina Lopez

Editor

Sabrina Lopez is a senior editor for Today’s Homeowner with over 7 years of writing and editing experience in digital media. She has reviewed content across categories that matter to homeowners, including HVAC services, home renovations, lawn and garden care, products for the home, and insurance services. When she’s not reviewing articles to make sure they are helpful, accessible, and engaging for homeowners like herself, Sabrina enjoys spending time with her family and their two parrots.

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