Choosing the right power tool: Brushed vs. Brushless motors compared

Choosing the right power tool can make a big difference in both performance and efficiency, whether you’re a DIY enthusiast or a professional contractor. One of the most important factors to consider is the type of motor inside your tool—brushed or brushless.

In recent years, cordless power tools have surged in popularity thanks to improvements in battery technology and motor design. As more users upgrade their toolkits, the question of “brushless vs. brushed” has become a key part of the decision-making process.

This article will give you a clear comparison of brushed and brushless power tools, covering everything from performance and efficiency to cost and lifespan. By the end, you’ll know exactly which option is best suited for your needs and budget.

What are Brushed Power Tools?

How Brushed Motors Work

Brushed power tools use a brushed motor, which relies on carbon brushes to transfer electrical current to the motor’s commutator. The brushes physically touch moving parts, creating friction that drives the motor and produces power.

Pros of Brushed Motors

• Lower Initial Cost – Generally more affordable than brushless tools.
• Simple Design – Straightforward motor structure makes them easy to manufacture and repair.
• Availability – Widely used in many entry-level and mid-range power tools.

Cons of Brushed Motors

• Shorter Lifespan – Brushes wear down over time and need to be replaced.
• Lower Energy Efficiency – Friction from brushes wastes energy as heat.
• More Maintenance – Requires periodic brush replacement and cleaning.
• Performance Loss Over Time – As brushes wear, the motor power output may gradually decrease.
• Noise – Friction between brushes and commutator makes them louder compared to brushless motors.

Brushed Motor Parameters at a Glance

What are Brushless Power Tools?

How Brushless Motors Work

Brushless power tools use a brushless motor, which eliminates the need for carbon brushes. Instead, they rely on electronic controllers to deliver current to the motor windings. This design reduces friction, improves efficiency, and allows the motor to adjust power output more intelligently based on the task.

Pros of Brushless Motors

• Longer Lifespan – No brushes to wear out, reducing mechanical friction.
• Higher Energy Efficiency – More power is converted into useful work, with less wasted heat.
• Better Performance – Delivers consistent torque and speed, even under heavy loads.
• Less Maintenance – No brushes to replace; requires less frequent servicing.
• Quieter Operation – Minimal friction means reduced noise levels.

Cons of Brushless Motors

• Higher Initial Cost – More advanced design and electronics make them more expensive.
• Complex Design – Requires electronic components that can be harder to repair.

Brushless Motor Parameters at a Glance

Key Differences Between Brushless and Brushed Power Tools

Performance

• Brushless Tools: Deliver more consistent power, provide better torque control, and adjust output automatically for demanding tasks.
• Brushed Tools: Performance can decline over time as brushes wear down, leading to less consistent power delivery.

Energy Efficiency

• Brushless Tools: Convert more electrical energy into usable power, resulting in longer battery life.
• Brushed Tools: Less efficient because friction from brushes wastes energy as heat.

Lifespan and Maintenance

• Brushless Tools: Longer lifespan due to no brushes, with minimal maintenance required.
• Brushed Tools: Shorter lifespan; brushes wear out and need replacement over time.

Cost

• Brushless Tools: Higher upfront cost due to advanced design and electronics.
• Brushed Tools: Lower purchase cost, making them budget-friendly.

Noise

• Brushless Tools: Operate more quietly since there is no brush-to-commutator friction.
• Brushed Tools: Louder because of brush contact and friction during operation.

Comparison Table: Brushless vs. Brushed Power Tools

Popular Power Tool Examples

Drills

Brushless Drills

Provide longer runtime, higher torque control, and better performance for heavy-duty drilling tasks such as woodworking or metalworking.

Brushed Drills

More affordable, suitable for light drilling jobs and occasional home projects.

Impact Drivers

Brushless Impact Drivers

Deliver greater torque efficiency, adjust automatically to workload, and are ideal for repetitive fastening tasks.

Brushed Impact Drivers

Lower initial cost, good for occasional fastening but less durable under continuous use.

Circular Saws

Brushless Circular Saws

Offer higher cutting power, smoother operation, and longer runtimes, making them ideal for heavy-duty cutting tasks.

Brushed Circular Saws

Affordable option for basic cutting tasks, but may overheat or wear faster.

When to Choose Brushed Power Tools

Occasional Use

Ideal for users who only need a tool a few times per year. Common for light household tasks, small DIY projects, or emergency repairs.

Budget-Friendly Option

Lower upfront cost makes them accessible for beginners or those not ready to invest in higher-end tools. Great for users who don’t need advanced features or long runtimes.

Simpler Maintenance and Repairs

While brushes wear out, they are relatively easy and inexpensive to replace. Users with basic mechanical skills can often service brushed tools themselves.

When to Choose Brushless Power Tools

Professional and Heavy-Duty Use

Designed for daily or continuous operation in demanding environments. Provide consistent torque and power, making them suitable for construction, woodworking, and metalworking.

Frequent Users

Ideal for people who use tools regularly and need longer runtimes between charges. Helps reduce downtime since the battery lasts longer and the motor requires less maintenance.

Long-Term Investment

Higher upfront cost is balanced by fewer replacements, lower maintenance needs, and overall better durability. Saves money in the long run for professionals and serious DIY enthusiasts.

Precision and Performance Needs

Brushless motors deliver smoother operation and better torque control. Essential when working with tough materials or requiring accurate cuts and fastening.

Conclusion

Key Differences Recap

• Performance: Brushless tools deliver consistent power and torque; brushed tools may lose efficiency as brushes wear.
• Energy Efficiency: Brushless tools have longer battery life due to higher efficiency; brushed tools waste more energy as heat.
• Lifespan and Maintenance: Brushless tools last longer with minimal maintenance; brushed tools require periodic brush replacement.
• Cost: Brushless tools are more expensive upfront; brushed tools are budget-friendly.
• Noise: Brushless tools are quieter; brushed tools can be louder due to brush friction.

Choosing the Right Tool Based on Usage

Final Recommendation

• Brushed Power Tools: Best for beginners, occasional DIYers, or those on a tight budget.
• Brushless Power Tools: Best for professionals, frequent users, or anyone seeking long-term efficiency and performance.