Brushed vs Brushless Systems: What’s the Real Difference in Power Tools?
Brushed vs Brushless Systems: What’s the Real Difference in Power Tools?
Whether you're a weekend DIYer or a seasoned tradesperson, understanding the difference between brushed and brushless power tools is key to choosing the right tool for the job. This guide explains how each motor type works, their pros and cons, and why the right tool depends on your application needs.
What is a Brushed Motor?
Brushed motors use carbon brushes that make contact with a commutator to power the motor. While this system is straightforward and cost-effective, the friction generated causes heat buildup and brush wear over time, requiring occasional maintenance.
What is a Brushless Motor?
Brushless motors eliminate the need for brushes by using an electronic controller. This design improves efficiency, reduces heat, minimises maintenance, and extends the lifespan of the tool. These motors are also typically quieter and more compact.
Brushed vs Brushless: Pros & Cons
Brushed Tools
- ✅ Lower upfront cost
- ✅ Allows easy owner maintenance
- ❌ Shorter lifespan due to brush wear
- ❌ Generates more heat and friction
- ❌ Noisier operation
Brushless Tools
- ✅ Longer lifespan
- ✅ Better energy efficiency
- ✅ Quieter and cooler operation
- ✅ Compact design
- ❌ Higher upfront cost
Comparison Overview
| Feature | Brushed Motor | Brushless Motor |
|---|---|---|
| Efficiency | Lower due to friction | Higher with electronic control |
| Maintenance | Requires brush replacement; allows owner maintenance | Minimal maintenance required |
| Durability | Moderate lifespan | Longer lifespan |
| Heat & Noise | Hotter and noisier | Cooler and quieter |
| Tool Size | Usually larger | More compact design |
Exploded View: Inside a Brushless Drill
This exploded view of a Kinway brushless drill shows how brushless motors reduce moving parts while improving performance. Each component contributes to smoother operation and extended life:
*Image is for illustration purposes only.
Key Components:
- Brushless Motor
- Electronic Controller and Switch Assembly
- Battery Pack and Charger (Sold Separately)
- Keyless Chuck and Gearbox Assembly
Which One Should You Choose?
Brushed power tools are ideal for users who prefer tools that allow for easy owner maintenance, including the ability to replace worn brushes. They’re also often more budget-friendly.
Brushless power tools, on the other hand, are designed for users who prioritise minimal downtime and a longer overall lifespan. Their efficiency and durability make them well-suited for both light and demanding applications.
At Adendorff Machinery Mart, we offer both brushed and brushless tools across multiple ranges, including our popular MAC AFRIC and Kinway brands. Your ideal choice depends on how often you use your tools and your preference for maintenance versus performance.