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Brushed vs Brushless Motors: Which Is Better For Your Power Tools?

04 Aug.,2025

Brushed vs Brushless Motors: Which Is Better For Your Power Tools?

Everyone has seen or has had to use a power tool at some point or the other. Drills, circular saws, hammer-drills, jigsaws, grinders, and routers are different kinds of power tools. These tools are used at home, construction sites, industries to ease certain specialized tasks and perform them with higher accuracy.

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DC (Direct Current) motors are usually used for power tools and there are two types: Brushed and Brushless motors. It is crucial to know the difference between them, as it would help you know the one best-suited for your project specification.

What Is a Brushed Motor?

Brushed DC motors use DC with mechanical commutation to produce mechanical energy. The stator is the fixed part of the motor located on the outside and contains a permanent magnet or an unmoving electromagnet coil and is responsible for creating the magnetic field. Here is how it happens:

Brushes in the motor allow the electricity from the DC power supply to flow into the rotor.
The rotor is located on the inside of the motor and consists of the armature, commutator, and coils winding. While rotating, it receives current from its connection to the collector.
The coil ends are connected to the commutator, and then the commutator is connected to the brushes. When the brushes and commutator are in contact, a direct current flows through the armature and coils windings.
As electricity passes through the coils, the electricity turns the coils into a temporary magnet, an electromagnet acts on it, and it interacts with the magnetic field lines of the permanent stator field.
The attraction and repulsion between the magnets on the stator and rotor cause the rotation of the rotor.
As rotation continues, it reaches a point where the brushes and commutator are no longer in contact, and the rotor stops spinning. However, the commutator makes contact with the stator and reverses the magnetic field, and allows the rotor to keep spinning.

There is the presence of friction between the brushes and the commutator, and as it is electrical contact, the friction cannot be eliminated by lubrication. This causes wear and tear in the brushes and commutator and brings the need for maintenance and replacement as time goes on.

What Is a Brushless Motor?

The brushless DC motor is also known as electronically commutated motor and it has the capability to convert alternating current (AC) to direct current. Brushless electric motors also work on the principle of attraction and repulsion of magnets.

As the name implies, these motors do not have brushes. This property (or the lack of it) eliminates the need for maintaining contact between the rotor and stator, and flipping the electromagnetic field to keep the electric current flowing through the coil of the motor.

In brushless motors:

The rotor consists of a permanent magnet, and the stator includes electromagnets, unlike in brushed DC motors, in which the rotor consists of electromagnets, and the stator consists of permanent magnets.
The stator has windings and coils and these windings activate the stator’s electromagnet.
The torque of the brushless DC motor is caused by the interaction of the electromagnets on the permanent magnets.
The stator can be controlled electrically by an electrical control system, i.e., they can be turned on and off.

Therefore, switching the stator's controls causes the rotor to rotate, generating mechanical energy. The presence of more coils in the rotor makes the rotation smoother.

Differences Between Brushed Motor and Brushless Motor

Below are major differences between these motors that make one of them better suited for power tools than the other.

1.How They Work

The significant difference between brushed and brushless motors is what causes engine rotation. In brushed DC motors, brushes and mechanical commutators are used to pass current into the coils of the engine for engine rotation. Meanwhile, in brushless DC motors, electrical commutation is used to pass current to the coils in the engine to cause rotation in the motor.

2.Speed

Due to arcing of the brushes in brushed DC motors, there are rotor limitations and low rotation speed. However, in brushless speed there are no brushes, and the presence of electrical commutation allows the brushless DC motor to produce a wider range of speeds. The brushless motor has a higher speed than the brushed motor.

Also, the brushless motor is more effective when the tools that it is being used require precise control of speed and torque. The speed and torque of a brushless motor can be controlled to give different ranges, while a brushed DC motor cannot.

3.Cost

The construction of a brushed motor does not require much high end technology; therefore, it is relatively cheaper than the brushless motor. Brushless motors are more expensive as they consist of advanced technology like the electrical commutation and electrical controller. It is important to note that the presence of this electrical commutator instead of a brush removes the need for maintenance and replacement and wear and tear in the engine, which in turn lengthens the life span.

Also, the installation costs of a brushless motor are much more than that of a brushed motor. Therefore, when the cost is a determining factor for your tools, the brushed motor is a better choice. However, it is essential that you should not sacrifice efficiency for costs when choosing your tools.

4.Noise Production

Due to the electrical contact between the brushes and the mechanical commutator in the brushed motors, friction is present; sparks are produced in these areas and noise is produced.

The presence of an electrical commutator in the brushless motor instead of brushes makes it have less noise than the brushed motor, as both the sparking, and friction noises are eliminated. Consequently, in devices where less noise is required, the brushless motor is a better choice.

5.Maintenance

As a result of friction between the brushes and the mechanical commutator in brushed motors, there is wear and tear in them. This requires a periodic change of both the brushes and commutators. However, this constant wear of the brushes and commutator can affect the motor itself, and in the long run, the whole motor system would require a change.

As the brushless motor does not contain these parts, this type of maintenance and repairs are not needed. With this, it is clear that the brushed motor requires more maintenance than the brushless motors.

The absence of friction in the brushless motor checks overheating, bringing about more efficiency and a longer life span for the device. Having to change the machine parts and deal with repairs constantly can be stressful, so a brushless motor is a better choice if you want to avoid this.

6.Safety

When safety is of priority, the brushless motor is a better choice as the use of the electrical commutator in place of brushes and mechanical commutators prevents electrical sparking. As a result of this, brushless motors can be used in flammable areas or hazardous environments. Brushed motors are not suitable for places where there is a risk of flammability. They also pro office a high amount of heat energy which may also worsen it's safety prospects.

7.Electrical Consumption

In brushless motors, electronic controllers which have a sensor are used to determine the accurate position of the rotor magnets and know which coil to supply current. This mechanism makes the current supply adjustable automatically. With this, electrical consumption can be reduced in brushless motors. Also, due to less heat dissipated by the brushless motor, they are not harsh on the environment compared to the brushed motors.

8.Efficiency

The presence of friction affects the efficiency of any machine. Friction causes more effort than required to be put into the engine for valuable work to be done. This makes the efficiency of a brushed motor lower than that of a brushless motor as energy is lost to friction and heat energy.

What does this mean? It means that for the same power input, a brushless motor would be more efficient and would convert more electrical energy to mechanical energy than a brushed motor. Therefore, in tools where efficiency is required, the brushless motor is the best choice.

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9.Equipment Lifespan

Since there is no friction, wear and tear and, need for regular servicing in a brushless motor, they tend to have a longer lifespan than their counterparts. On the other hand, the design of the brushed motor makes it have a shorter life span. This is because the brushes get worn away with use.

How to Choose Your Power Tools

In choosing power tools, the first step is to determine the purpose the device is intended to serve (would you use it for your daily business, or is it simple household equipment). Then do your research to find the tools with the best features that would serve that purpose.

After deciding on the best tool that would serve that purpose, before you make your final choice, you’ll need to:

Compare the different brands and manufacturers of your chosen tool available on the market
Consider and compare the safety of the tool, the warranty, the efficiency, power or electrical consumption
Finally compare the cost of the tools to your budget

These steps would help you choose a power tool and ultimately the right kind of motor your looking out for. Are you looking for something simple, light and portable? Or are you looking for something that is low-cost with readily available parts? What qualities are you willing to forgo and what qualities cannot be compromised? Depending on what tool you want, you’ll have to look at the advantages and disadvantages of both brushless and brushed DC motors.

Brushless vs Brushed: Pros and Cons

Brushed and brushless motors have different properties, features and functionalities. Below are tables showing the pros and cons of bot brushless and Brushed motors.

1. Brushless Motor

Pros

High efficiency
High and wide range of speed
Little to no electrical noise
Longer life span
Elimination of the need for maintenance and replacement.
It is safe for use even in a hazardous environment
Compact, light and portable

Cons

Relatively high cost compared to the brushed motor
High complexity

2. Brushed Motor

Pros

A simple device. Suitable for tools that require less complexity
Low cost of installation
It can be easily repaired compared to a brushless motor

Cons

Requires regular maintenance and replacement of worn out parts
Friction between the parts makes it prone to sparking
Not suitable for environments with a risk of flammability
Short life span
Less efficient when compared to the brushless motor
It produces high electrical noise
Lacks portability

Note: When choosing power tools do not sacrifice efficiency for cost, a more efficient but expensive tool might end up costing less in the long run when compared to a less efficient but cheap tool after adding the cost of repairs and maintenance accrued over the same period.

Brushed vs Brushless: Litheli Power Tools Comparison

1. Paint Sprayer

Below is a comparison between the Litheli 20V Cordless HVLP Paint Sprayer and the Litheli 20V Brushless Electric Paint Sprayer (Effort-saving Version).

Litheli 20V Cordless HVLP
Paint Spayer

It has three nozzles that are easily washed and replaced.
It has fast charging and a Li-ion battery to safeguard the powering process.

Litheli 20V Brushless Electric Paint Sprayer

It has 4 nozzles with adjustable knob to control flow and prevent paint wastage.
Has a long service life and reduced noise because of its brushless motor.

2. Leaf Blower

Below is a comparison between Litheli 40V Brush-motor Battery Leaf Blower and the Litheli 40V Brushless Single-tube Electric Leaf Blower.

Litheli 40V Brushed-motor Battery Leaf Blower

Powerful axial turbine
High-efficiency brushed motor
It weighs 4.1 lbs
85 MPH speed + 350 CFM volume
Easy assembly with a snap-on tube

Litheli 40V Brushless
Electric Leaf Blower

Axial fan that generates airflow with higher strength
Brushless motor with 40% higher efficiency than brushed models
It weighs 5.7 lbs
It has 45-76 MPH variable speed control + Turbo mode runs at 480 CFM
Metal scraper helps wipe off debris

Conclusion

After looking at the features, working mechanism, and pros and cons of the brushed and brushless motor, it can be inferred that the brushless motor is a better option for most power tools than the brushed motor. However, the brushed motor has its advantages in some areas of application. For example, it is ideal for tools that are not frequently used and do not require a high level of speed and precision.

Due to its many benefits and high efficiency, the brushless motor is widely used for many power tools and is quickly replacing the brushed motor.

Top 10 Best Cordless Power Tools for DIY Workshop

In the world of DIY and home improvement, having the right tools can make all the difference. For both seasoned handypeople and beginners alike, cordless power tools offer unparalleled convenience, flexibility, and efficiency in tackling a wide range of projects.

In this comprehensive article, we will delve into the top 10 best cordless power tools that every DIY workshop should have.

Contents

Advantages of Cordless Power Tools Over Corded Tools
How to Choose the Right Cordless Power Tool Platform
Top 10 Best Cordless Power Tools
Additional Factors to Consider When Choosing Cordless Power Tools
Safety Tips for Using Cordless Power Tools
Conclusion

Advantages of Cordless Power Tools Over Corded Tools

Mobility and Flexibility

Cordless power tools allow you to work freely without being tethered to a power outlet, making it easier to tackle projects in remote or hard-to-reach areas.
The absence of cords also reduces the risk of tripping hazards and entanglement while working.

Compact and Lightweight Design

Cordless power tools are generally lighter and more compact than their corded counterparts, making them easier to handle and maneuver, especially during extended use.

Improved Technology and Performance

Advancements in battery technology have significantly increased the power, runtime, and overall performance of cordless power tools, making them a viable alternative to traditional corded tools for many applications.

How to Choose the Right Cordless Power Tool Platform

When investing in cordless power tools, it's essential to choose a platform that best suits your needs. Here are some factors to consider when selecting a cordless power tool platform:

Battery Voltage

Cordless power tools are available in various voltage ranges, such as 12V, 18V, and 20V. Higher voltages typically offer more power but may be heavier and bulkier. Consider the type of projects you'll be working on and choose a voltage range that provides an appropriate balance of power and portability.

Tool Selection

Some brands offer a wider range of cordless power tools within their platforms, giving you more options to expand your collection. Consider the variety of tools available within a platform and ensure they align with your specific needs and preferences.

Price and Value

Cordless power tool platforms can vary significantly in price. Determine your budget and compare the cost of tools, batteries, and accessories across different platforms to find the best value for your investment.

Top 10 Best Cordless Power Tools

1. Cordless Drill/Driver

Functionality: The cordless drill/driver is the most essential power tool for any DIY enthusiast. Combining drilling and screw-driving capabilities, it can be used for a myriad of tasks, from hanging shelves to assembling furniture.
Key Features: Look for a drill with multiple speed settings, an adjustable clutch for precise torque control, and a comfortable grip for extended use.

2. Cordless Impact Driver

Functionality: A cordless impact driver is designed to deliver higher torque compared to a standard drill/driver. This makes it ideal for driving large screws and bolts, as well as removing stubborn fasteners.
Key Features: A brushless motor offers increased power and longer runtime, while a variable-speed trigger gives you greater control over the tool's performance.

3. Cordless Circular Saw

Functionality: A cordless circular saw is perfect for cutting wood, plywood, and other sheet materials with ease. It's a must-have for framing, decking, and other carpentry work.
Key Features: Look for a model with a powerful motor, easy-to-adjust blade depth, and bevel settings for versatile cutting options.

4. Cordless Jigsaw

Functionality: A cordless jigsaw is a versatile cutting tool that allows you to make curved and intricate cuts in various materials such as wood, metal, and plastic.
Key Features: Key features to look for include variable speed control, orbital action for faster cutting, and an easy-to-change blade system.

5. Cordless Reciprocating Saw

Functionality: Also known as a "Sawzall," a cordless reciprocating saw is designed for demolition work, cutting through wood, metal, PVC, and more. It's great for remodeling projects and cutting materials in tight spaces.
Key Features: Look for models with variable speed control, a comfortable grip, and tool-free blade changes.

6. Cordless Oscillating Multi-Tool

Functionality: A cordless oscillating multi-tool is a versatile device that can perform various tasks, such as sanding, cutting, scraping, and grinding. It's perfect for detail work and hard-to-reach areas.
Key Features: Quick and easy accessory changes, variable speed control, and a compact design are essential features to consider.

7. Cordless Angle Grinder

Functionality: A cordless angle grinder is used for cutting, grinding, and polishing metal, concrete, and other materials. It's an indispensable tool for metalworking, masonry, and construction projects.
Key Features: Look for a model with a powerful motor, variable speed control, and a comfortable grip.

8. Cordless Brad Nailer

Functionality: A cordless brad nailer allows you to drive nails without the need for a compressor or hose. It's perfect for trim work, baseboards, crown molding, and other finish carpentry tasks.
Key Features: Key features include a depth-of-drive adjustment, anti-dry-fire mechanism, and a no-mar tip to protect your work surface.

9. Cordless Leaf Blower

Functionality: A cordless leaf blower is an essential tool for keeping your workshop clean and free of dust, debris, and leaves. It's also great for quick cleanups around the yard.
Key Features: Look for a model with variable speed control, a lightweight design, and a long runtime.

10. Cordless LED Work Light

Functionality: A cordless LED work light provides bright, portable illumination for your workspace, ensuring that you can see clearly while working on your projects.
Key Features: Important features include an adjustable head, multiple brightness settings, and a durable, weather-resistant design.

Additional Factors to Consider When Choosing Cordless Power Tools

Battery Compatibility

Importance: Many cordless power tools use interchangeable batteries, allowing you to use the same battery for multiple tools within the same brand's product line. This can save you money and reduce the number of chargers cluttering your workspace.

What to Look For: Check if the cordless power tool you're considering is compatible with batteries from other tools you own or plan to purchase. Stick to a single battery platform when possible.

Ergonomics and Comfort

Importance: Comfortable and ergonomic design is crucial for extended use and preventing fatigue and injury during DIY projects.
What to Look For: Look for tools with comfortable and well-designed grips, balanced weight distribution, and minimal vibration.

Tool Warranty and Customer Support

Importance: A good warranty and customer support from the manufacturer can provide peace of mind and ensure that you get the most out of your investment.
What to Look For: Consider brands with strong warranties and a reputation for excellent customer service. Read user reviews to gauge the quality of the company's after-sales support.

Safety Tips for Using Cordless Power Tools

Read the User Manual

Familiarize yourself with the tool's features, operation, and safety precautions by reading the user manual before using it for the first time.

Wear Proper Protective Equipment

Always wear appropriate safety gear, such as safety glasses, hearing protection, and gloves, when using cordless power tools.

Use the Right Tool for the Job

Using the wrong tool for a specific task can lead to accidents and damage to the tool or your project. Ensure that you are using the correct tool and accessory for the job at hand.

Keep Your Workspace Clean and Organized

A cluttered workspace can increase the risk of accidents and make it difficult to find the tools and materials you need. Keep your workshop clean, well-lit, and organized to create a safe and efficient working environment.

Follow Proper Tool Operation and Maintenance Procedures

Using your cordless power tools according to the manufacturer's recommendations and performing regular maintenance will help ensure their safe and efficient operation.

Cordless Tool Storage and Organization Solutions

Maintaining an efficient workspace requires not only dedication but also a strategic approach to tool storage. The advent of cordless tools, with their myriad shapes, sizes, and accessories, presents a unique organizational challenge. An optimal solution encompasses not just the physical placement of tools but also considers ease of access, tool protection, and the ability to adapt to changing tool collections.

Innovations in modular storage systems, designed specifically for the versatility and specific needs of cordless tools, are reshaping how professionals and hobbyists alike keep their gear in check. These systems prioritize adaptability, allowing users to rearrange and expand their storage configurations as their collections grow, ensuring that organization is not just about storage, but about creating a seamless workflow.

Customizable Shelving Units

Adding another dimension to tool organization, some customizable shelving units now incorporate smart technology, enabling users to track which tools are in use and which are stored. This integration can be particularly useful in professional settings where multiple workers share tools, ensuring accountability and minimizing loss or misplacement. By leveraging technology, these smart shelves offer a glimpse into the future of tool organization, where efficiency and technology converge to create a harmonious workspace.

Portable Tool Boxes and Bags

In the realm of portable tool storage, advancements in material science have led to the development of lighter, yet more durable tool boxes and bags. These next-generation storage solutions utilize high-impact resistant polymers and reinforced fabrics to withstand the rigors of transport and daily use without adding significant weight. Such innovations not only protect the tools within but also contribute to the overall mobility and convenience that are hallmarks of cordless tool systems, making the task of carrying and protecting one's investment less burdensome.

Conclusion

Investing in the right cordless power tools can significantly enhance your DIY workshop experience. With the top 10 best cordless power tools listed above, you'll be well-equipped to tackle a wide range of projects with ease and efficiency.

Remember to consider factors such as functionality, key features, and brand reputation when selecting your tools. Happy building!

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Brushed vs Brushless Motors: Which Is Better For Your Power Tools?