Brushless vs. Brushed Motors: What’s the Difference

I have spent a lot of time tinkering with tools and taking on DIY projects, I’ve come across a wide variety of power tools in all shapes and sizes. One of the things I’ve learned is that the type of motor inside these tools can significantly impact their performance, durability, and efficiency. If you’ve ever looked into buying a cordless drill, saw, or impact driver, you’ve likely stumbled upon the terms “brushed” and “brushless.” At first glance, it might not seem like a big deal, but once I really dug into the details, I realized how crucial the choice between the two can be.

Let me walk you through everything I’ve learned so far in the great debate of brushless vs. brushed motors. Whether you’re upgrading your workshop or just want to know why one tool costs more than another, this breakdown should help you make smarter buying decisions.

What Makes a Motor “Brushed” or “Brushless”?

Every electric motor has a simple job: convert electrical energy into mechanical energy. In both brushed and brushless motors, magnets and coils work together to make that happen. But the way they interact is what sets them apart.

In brushed motors, small carbon brushes come into direct contact with a spinning metal commutator to send current through the coils. This physical contact is necessary to keep the motor running. The commutator and brushes continuously rotate and maintain electrical flow. It’s an older, proven design that’s been used for decades in everything from toys to power drills.

Brushless motors, on the other hand, ditch the brushes entirely. Instead of relying on physical contact to control current, they use an electronic controller. This controller switches the direction of the current, allowing the motor to spin without friction from brushes. It’s a more modern approach that comes with several advantages—but also a few trade-offs.

Performance Differences on the Job

I’ve used both types of motors on various jobs, and the performance gap is noticeable once you’re familiar with the tools. Brushless motors generally deliver more power and better efficiency. They adjust themselves to the task at hand, meaning they draw only as much power as they need. That saves energy and leads to longer battery life, especially during heavy-duty use.

Brushed motors, on the other hand, operate at a constant speed regardless of load. They don’t have the ability to self-adjust, so they tend to burn through battery life faster when under stress. That’s something I’ve noticed when using older drills that heat up quickly and need frequent charging.

Durability and Longevity

Durability is where brushless motors really shine. Since there are no brushes making contact inside the motor, there’s less wear and tear over time. That means fewer parts to replace and a longer life span overall. I’ve had brushless tools that kept working like new even after years of abuse in the garage.

Brushed motors, because of their physical contact points, naturally wear down. Eventually, those carbon brushes will degrade and need replacement. It’s not the end of the world, but it does mean more maintenance, especially if you use the tool frequently or in dusty, dirty conditions.

Heat and Noise Output

Another major area of difference is heat. Brushless motors run cooler. Without the friction caused by brushes rubbing against the commutator, there’s simply less heat generation. That’s a big win when working in tight spaces or during extended use, as your hand and the motor don’t get uncomfortably hot.

Brushed motors, due to that constant friction, produce more heat. They also tend to be noisier. I’ve found that when I’m cutting through thick wood or drilling into masonry with a brushed motor, the tool gets hot fast and emits that telltale buzzing noise that can become irritating over time.

Efficiency and Battery Life

Brushless vs. brushed motors really start to separate when it comes to energy efficiency. I’ve noticed my brushless tools can last significantly longer on a single battery charge. This is especially helpful for cordless tools, where battery runtime can make or break a project timeline.

Because brushless motors are electronically controlled and adjust according to the workload, they waste less power. Brushed motors run at full tilt no matter what you’re doing, which can drain batteries faster and create more downtime.

Cost Considerations

Let’s talk dollars and cents. Brushless tools often come with a higher price tag. That’s mostly due to the more complex electronics involved in controlling the motor. When I first started investing in my workshop, I hesitated to pay the premium for brushless. But after burning through a couple of cheaper brushed tools, I quickly realized the extra cost can be worth it in the long run.

Brushed tools are more budget-friendly and still get the job done, especially for occasional or light use. If you’re a weekend warrior who pulls out the drill a few times a year, brushed tools might be more than sufficient. But for someone like me, who’s working with tools multiple times a week, the durability and efficiency of brushless models have paid off.

Maintenance and Repairs

Brushless motors require very little maintenance. Since there are no brushes to replace and less friction overall, you can pretty much just use the tool and store it without worrying much. That kind of peace of mind is worth a lot, especially if you’ve got multiple tools in rotation.

Brushed motors do require some upkeep. The brushes will eventually wear down and need replacing, and you’ll probably have to clean out dust and debris more frequently. I’ve had brushed tools fail mid-job simply because I hadn’t checked the brushes in a while. It’s not difficult to fix, but it adds another thing to your to-do list.

Tool Size and Design Flexibility

Brushless motors tend to be more compact. Because they don’t need space for brushes or a commutator, manufacturers can design sleeker and lighter tools. I’ve noticed that many newer brushless drills and drivers feel more balanced in hand, making them easier to use for longer periods.

Brushed motors take up a bit more space and can make tools feel bulkier. That may not seem like a big deal until you’re working overhead or in tight corners where every ounce and inch counts. For intricate or fatigue-heavy work, the smaller size of brushless tools is a noticeable benefit.

Applications That Matter

Some tools benefit more from being brushless than others. High-torque tools like impact drivers and circular saws really take advantage of the improved power and efficiency. I’ve seen my brushless impact driver sink screws faster and more consistently than its brushed predecessor.

For tools that aren’t used as aggressively—like jigsaws or detail sanders—the difference between brushless vs. brushed motors might be less dramatic. In those cases, opting for the cheaper brushed version could be a smart way to save money.

Longevity in Cordless Systems

Cordless platforms thrive with brushless technology. If you’re already committed to a battery system—like Milwaukee M18, DeWalt 20V MAX, or Makita LXT—you’ll find that their best-performing tools tend to be brushless. These tools maximize runtime and minimize downtime, which has changed how I approach larger jobs.

With brushed tools, battery life is the main constraint. Even with spare batteries, I used to find myself charging more than working. That all changed once I started upgrading to brushless gear across my setup.

Environmental Impact and Efficiency

One overlooked factor is environmental impact. Brushless motors, by consuming less power and generating less heat, are more energy-efficient. While that might not be a top priority for every DIYer, it’s something I think about when choosing tools. Fewer replacements, less energy consumption, and less e-waste all add up over time.

Brushed motors, with their higher energy draw and disposable brushes, just aren’t as eco-friendly. If sustainability matters to you, this could tip the scales in favor of brushless.

Final Thoughts on Tool Investment

So, brushless vs. brushed motors—what’s the difference? In short: brushless offers better performance, less maintenance, longer battery life, and more durability. Brushed motors provide a more affordable entry point and are still reliable for light or occasional use.

After years of DIY work, I’ve shifted the bulk of my toolkit toward brushless models. The upfront cost is higher, but the benefits in day-to-day use are impossible to ignore. That doesn’t mean I’ve tossed all my brushed tools. I still keep a few for backup or loaning out to friends who are getting started. But when it comes time to invest in something new, I’m looking at brushless first every time.

In the end, it all comes down to your needs, your budget, and how often you plan to use the tool. If you’re serious about DIY projects or just want fewer headaches with maintenance and charging, brushless motors are worth the investment. If you’re just building a basic toolkit or don’t use your tools often, brushed models will still serve you well.