When it comes to cordless drills, you have two main options for the motor that powers these handy tools – brushed or brushless. But what exactly is the difference between brushed and brushless drill motors? And is one actually better than the other?
In this blog post, you’ll learn how they work, key differences in performance and maintenance, and whether a pricier brushless model is worth the investment over a standard brushed cordless drill.
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Brushed DC Motors – The Traditional Workhorse
First, let’s take a quick look at how good ol’ brushed DC motors operate. They’ve been powering cordless drills for many years and still offer a solid, budget-friendly performance.
Brushed motors work by passing current from the battery to the stationary windings of the motor. The current generates a magnetic field which causes the armature to spin. But here’s the key – the armature’s orientation needs to change for the motor to keep rotating.
That’s where the brushes and commutator come in. The commutator is a cylinder on the armature that rotates with it. The brushes press against the commutator, redirecting the current to flip the magnetic poles as needed. This keeps the continuous motion going.
Over time, the brushes wear down from friction against the commutator. This is one of the downsides of brushed motors. The brushes will need periodic replacement as they degrade.
Now let’s look at the pros and cons of these traditional brushed drill motors:
Features of Brushed Motors
Brushed DC Motor
- Relatively simple mechanical design
- Lower manufacturing costs
- Affordable brushed drill options
Require Maintenance
- Brushes wear down from friction
- Need replacing over time
Lower Efficiency
- Brushes and commutator create friction
- Causes some energy loss
So in summary, brushed motors have been the affordable, go-to choice for cordless drills. But they come with the tradeoff of lower efficiency and the need for periodic brush maintenance.
Brushless DC Motors – The Newer Performance Option
Now let’s look at the newer kid on the block – the brushless DC motor. Over the past decade or so, power tool manufacturers have increasingly moved to brushless motors for their higher power and efficiency.
So how do these high-tech motors work their magic?
How Brushless Motors Operate
Instead of brushes and a commutator, brushless motors use electronics to control the rotation. The key components are the stator, rotor, and electronic speed controller.
The stator contains permanent magnets that generate a magnetic field to spin the rotor. The speed controller determines the timing and polarity of the stator’s magnetic field. This electronic commutation is what keeps the rotor continuously spinning.
Without brushes and a commutator, brushless motors avoid those sources of friction and energy loss. This makes them more efficient while also being more durable and requiring less maintenance.
Benefits of Brushless Motors
Now let’s look at some of the biggest advantages of brushless drill motors:
Higher Efficiency
- Avoid brush/commutator friction
- Less wasted energy
More Power
- Generate higher torque
- Better for heavy duty tasks
Increased Durability
- No brushes to wear out
- Bearings better protected
Less Maintenance
- No brush replacements needed
The downside is that the electronic speed controllers make brushless motors more complex. This means they cost more to manufacture overall.
However, the performance benefits often make brushless motors worth the higher price for serious DIYers or professional use.
Key Differences Between Brushed and Brushless Drills
Now that we’ve covered how brushed and brushless motors operate, let’s directly compare some of the key differences between them:
Power and Efficiency
- Brushless motors are more powerful and efficient. They generate less internal friction and waste less energy as heat.
- Brushed motors have more friction from the brushes. This makes them less efficient and limits their maximum power.
Torque
- Brushless motors can produce higher torque, especially at lower speeds. Their direct drive provides full torque immediately.
- Brushed motors have lower torque capabilities, making them less suitable for driving large screws or boring holes.
Maintenance
- Brushed motors require more maintenance as the brushes wear down over time. The brushes will need periodic replacement.
- Brushless motors don’t have brushes, so they don’t require any brush maintenance.
Cost
- Brushless drills are more expensive than brushed models, often $50+ more for a comparable model. The complex electronics increase manufacturing costs.
- Brushed drills are generally more budget-friendly. The simpler mechanical design results in lower production costs.
As you can see, there are some clear tradeoffs between these two modern motor technologies. Next, we’ll provide some guidance on choosing between them for your needs.
Which is Better – Brushed or Brushless Drill?
So when it comes down to deciding between brushed and brushless, which type of drill is right for you? Here are some tips:
When to Choose a Brushed Drill
If you’re on a budget – Brushed models provide very capable performance for most DIY tasks, at a lower price point. If you need to watch your wallet, a brushed drill is a good option.
For lighter duty tasks – Occasional around-the-house jobs don’t require the highest power and torque. Brushed drills work fine for screwing in fixtures, assembling furniture, and basic projects.
As a backup drill – Having a brushed model as a secondary drill can be useful for loaning out or as insurance against your primary drill failing.
When to Choose a Brushless Drill
For heavy duty use – Frequent high-torque tasks like drilling, fastening, and driving large screws in hard materials benefit from a more powerful brushless motor.
If longevity is key – The increased durability and lack of brushes to replace makes a brushless drill a long-lasting choice for frequent use.
For professional/jobsite use – Contractors and construction crews need drills that can handle the rigors of daily professional work. Brushless models are up to the task.
For advanced users – DIY enthusiasts, makers, and garage tinkerers will appreciate the higher performance of brushless for their projects and hobbies.
Match the Drill to Your Needs and Budget
As you can see, there are good reasons to choose both brushed and brushless drills depending on your needs and budget.
Brushed motors offer time-tested performance at a more affordable price point. They work well for light DIY use.
Brushless motors provide more power, efficiency, and durability. They justify their higher cost for frequent and heavy duty use.
By understanding the key differences between these two motor types, you can pick the best cordless drill for your toolbox and bank account!
The Final Take – Key Factors in Deciding Between Brushed and Brushless
When choosing between brushed and brushless cordless drills, there are three major factors to consider:
Power and Runtime – Brushless motors are more powerful and efficient, providing faster drilling/driving with longer battery life. Brushed gets the job done but brushless performs better.
Maintenance – Brushed motors require periodic brush replacements while brushless are nearly maintenance-free. This makes brushless the more convenient and durable choice.
Cost – The complex electronics of brushless motors come at a price premium. Brushed models are easier on the wallet. But brushless provides better value over its longer lifespan.
For professional contractors or avid DIYers, the extra performance of brushless is likely worth the higher price tag. Casual users on a budget may be better served by an affordable brushed model.
Make sure to realistically assess your needs and how often you use a cordless drill. And don’t underestimate how handy it can be to have both brushed and brushless drills in your collection for different scenarios.
At the end of the day, you can’t go wrong with either motor type. Just match the drill to your budget and usage to get the right tool for the job!
Still Have Questions? Here are the Most Common FAQs about Brushed and Brushless Drills
What’s the difference between a driver and drill?
A drill is made for drilling holes, while a driver is made for driving screws and fasteners. Many cordless tools now combine both functions into a drill/driver. Both brushed and brushless motors are used in drill/drivers.
Do brushless drills need special batteries?
No, you can use the same lithium-ion batteries in brushed and brushless tools. Just be sure to use batteries that match the voltage (typically 18V or 20V).
How much more expensive are brushless drills?
Expect to pay $50 to $100 more for a brushless model compared to an equivalent brushed drill. The price gap has narrowed over time but still exists.
Do brushless drills overheat less?
Yes, the increased efficiency results in less heat buildup so brushless drills tend to run cooler under heavy use. This allows for longer continuous runtime before overheating.
Is a brushless drill worth it for a home DIYer?
For light duty home use, a brushed drill is usually sufficient. But avid DIYers may appreciate the extra power and smoothness of brushless motors for tougher tasks.
Do I need to break in a new brushless drill?
No break-in is required. Just charge up the battery and start using and enjoying your new brushless drill!
