A no-nonsense guide to brushed and brushless motor technology in power tools — how they work, what the real-world differences are, and whether the price premium is worth it for UK tradespeople.
Walk into Screwfix or Toolstation today and you’ll notice that almost every cordless power tool comes in two versions: a standard model and a “brushless” model. The brushless version typically costs 20–30% more and promises better performance, longer battery life, and increased durability. But what does “brushless” actually mean? Is it genuinely worth the extra money, or is it just another way for manufacturers to charge more for a sticker on the box?
The short answer is that brushless motors are a genuine improvement over brushed motors — but the difference matters far more in some situations than others. This guide explains what’s actually happening inside your power tools, cuts through the marketing jargon, and helps you decide where to spend your money wisely.
How a Brushed Motor Works
Brushed motors have been the standard in power tools for decades. They’re a proven, well-understood technology that still powers millions of tools worldwide. Understanding how they work makes the benefits of brushless technology much clearer.
A brushed motor has four main components: permanent magnets (the stator) mounted on the outside, a set of wire coils wound around a shaft (the armature/rotor) that spins in the centre, a commutator that sits on the shaft, and carbon brushes that press against the commutator. When you pull the trigger on your drill, electrical current flows through the carbon brushes into the commutator, which feeds it to the wire coils. This creates an electromagnetic field that interacts with the permanent magnets, causing the armature to spin. The commutator constantly switches the direction of the current to keep the rotation going.
The key thing to understand is that the carbon brushes are in constant physical contact with the spinning commutator. This friction is what creates most of the limitations of brushed motors — it generates heat, wastes energy, causes wear on the brushes themselves, and limits how fast and efficiently the motor can run.
How a Brushless Motor Works
A brushless motor flips the arrangement. The permanent magnets move to the rotor (the spinning part), and the wire coils are fixed on the stator (the stationary part). There are no carbon brushes and no commutator. Instead, an electronic controller — essentially a small circuit board built into the tool — precisely controls the current flowing to each coil in sequence, creating a rotating magnetic field that spins the rotor.
This electronic controller is what makes brushless motors “smart.” It can monitor the resistance the tool is meeting and adjust the power output accordingly. Driving a screw into softwood? The controller dials back the current, saving battery. Hit a knot or switch to hardwood? The controller increases power to maintain speed. This adaptive behaviour happens thousands of times per second, entirely automatically.
The trade-off is complexity. A brushless motor requires sophisticated electronics that a brushed motor doesn’t need, which is the main reason brushless tools cost more. But that electronic controller also enables features that would be impossible with a brushed motor — including the smart tool technology used by platforms like Milwaukee ONE-KEY and Makita’s tool management systems.
Brushed vs Brushless: Head-to-Head Comparison
| Factor | Brushed Motor | Brushless Motor |
| How it works | Carbon brushes transfer current via physical contact | Electronic controller manages current with no physical contact |
| Efficiency | Lower — energy lost to friction and heat | Higher — up to 50% more efficient use of battery |
| Battery life per charge | Shorter runtime | 30–50% longer runtime on the same battery |
| Power output | Good, but limited by friction losses | Higher torque and speed from same voltage |
| Weight & size | Heavier, bulkier motor assembly | More compact and lighter |
| Noise level | Louder due to brush friction | Noticeably quieter operation |
| Maintenance | Brushes wear out and need replacing | Virtually maintenance-free motor |
| Motor lifespan | Shorter — brushes degrade over time | Significantly longer motor life |
| Heat generation | Runs hotter under load | Runs cooler, protecting electronics |
| Smart features | Not possible | Enables electronic speed/torque control |
| Spark risk | Can spark — caution in some environments | No sparking from motor |
| Price | £50–100 typical (drill) | £80–160 typical (drill) — ~30% premium |
Why These Differences Matter on Site
Battery Life
This is where most tradespeople notice the biggest real-world difference. A brushless drill or impact driver will get significantly more work done on a single battery charge than a brushed equivalent. If you’re working all day on site, that could mean the difference between getting through a shift on two batteries versus three or four. Fewer battery swaps, less time waiting for charges, and potentially fewer batteries to buy.
The efficiency gain is most pronounced during sustained, heavy use. If you’re driving hundreds of screws a day, drilling through masonry, or running a circular saw through sheet materials, the brushless motor’s ability to regulate power draw and minimise waste adds up dramatically over a full day.
Power and Performance
Brushless motors deliver more usable power from the same battery voltage because less energy is lost to friction and heat. In practical terms, a brushless 18V drill will typically outperform a brushed 18V drill in both torque and speed. This isn’t just about raw numbers on a spec sheet — it translates to faster drilling, easier driving of larger fixings, and less bogging down under load.
The “smart” power regulation also matters. A brushless tool that automatically increases power when it hits resistance and backs off when resistance drops gives you more consistent, controlled performance. Anyone who’s had a brushed drill suddenly grab and twist when it breaks through material will appreciate the smoother, more predictable behaviour of a well-designed brushless tool.
Size and Weight
Brushless motors can be made more compact than brushed equivalents at the same power level. This is why modern brushless impact drivers and drills are noticeably smaller and lighter than their predecessors. For tradespeople working overhead, in tight spaces, or carrying tools up scaffolding all day, this difference matters. A lighter, shorter impact driver that fits into confined spaces isn’t a luxury — it’s a practical advantage that affects your work every day.
Durability and Maintenance
Carbon brushes in a brushed motor are a wear item. Depending on usage, they typically need replacing every 50–100 hours of heavy use, or roughly every two to five years for most tradespeople. It’s not an expensive fix, but it’s downtime and hassle. A brushless motor eliminates this entirely. The motor itself should outlast every other component in the tool.
The reduced heat also protects the tool’s electronics, bearings, and battery connections. Brushless tools tend to have longer overall lifespans, which matters when you’re investing in a battery platform that you’ll be using for years.
Is Brushless Worth the Extra Money?
This is the question everyone actually wants answered, and the honest answer depends on how you use your tools.
Brushless is worth it if:
You use power tools daily as part of your trade. The battery life improvement alone pays for the price difference over time, before you even factor in the performance and durability benefits. If you’re a plumber, electrician, joiner, builder, or any trade that relies on cordless tools every working day, brushless should be your default choice for primary tools like drills, impact drivers, and circular saws.
Brushless might not be necessary if:
You’re a DIYer who uses power tools occasionally, or you’re buying a tool you’ll only use a few times a year. A brushed drill that costs £60 instead of £100 will serve perfectly well for weekend projects and occasional home repairs. The efficiency and lifespan advantages of brushless don’t offer meaningful value if the tool only comes out of the cupboard a few times a year.
The smart approach for tradespeople:
Go brushless on your primary, everyday tools — your drill, impact driver, circular saw, and any other tool you reach for daily. For specialist tools you use less frequently, or for backup tools kept in the van, brushed models can save money without meaningfully affecting your work. The price difference between brushed and brushless across a full tool kit can easily be £200–400, so being selective about where you invest in brushless makes financial sense.
What About Corded Tools?
The brushed vs brushless conversation is primarily about cordless tools, where battery efficiency is the key advantage. Corded tools draw power directly from the mains, so the battery life benefit — the single biggest advantage of brushless — doesn’t apply.
That said, brushless corded tools do still benefit from reduced heat, lower noise, and longer motor life. Some high-end professional corded tools use brushless motors, particularly heavy-duty options like plunge saws and routers where sustained performance matters. But for most corded tool purchases, the brushed vs brushless distinction is far less important than it is for cordless tools.
Brushless Lines from Major UK Brands
If you’re shopping for brushless tools in the UK, here’s how the major brands label their brushless ranges. Knowing these names helps you quickly identify which tools in a range are brushless and which aren’t.
| Brand | Brushless Range | Battery Platform | Key Note |
| Milwaukee | M18 FUEL / M12 FUEL | M18 / M12 | All FUEL tools are brushless; POWERSTATE motor |
| Makita | LXT Brushless / XGT | 18V LXT / 40V XGT | All XGT tools are brushless; some LXT are brushed |
| DeWalt | XR Brushless | 18V XR | Look for “DCL” vs “DCD” model prefixes |
| Bosch | ProCORE / Biturbo | 18V / ProCORE 18V | Biturbo line is brushless with dual-motor tech |
| Hikoki | MultiVolt | 18V / 36V MultiVolt | MultiVolt tools automatically switch 18V/36V |
| Ryobi | ONE+ HP | 18V ONE+ | HP line is brushless; standard ONE+ is brushed |
Common Myths About Brushless Motors
“Brushless motors produce more torque”
Not inherently. The motor design itself doesn’t automatically mean more torque. However, because brushless motors waste less energy on friction and heat, manufacturers can extract more usable power from the same battery and motor size. The result is usually higher torque in practice, but it’s a design benefit rather than a fundamental law of physics.
“Brushed tools are unreliable”
Not at all. Brushed motors have been powering professional tools for decades and continue to work well. Carbon brush replacement is routine maintenance, not a failure. A quality brushed tool from a reputable brand will give you years of reliable service. Brushless is better in most measurable ways, but “better” doesn’t mean the alternative is bad.
“You need new batteries for brushless tools”
Generally false. Most major brands maintain battery compatibility across their platform regardless of whether the tool is brushed or brushless. Your existing Makita 18V LXT batteries work in both brushed and brushless LXT tools. The same applies to DeWalt 18V XR, Milwaukee M18, and most other platforms. You’re not locked into buying new batteries when you upgrade to brushless.
The Verdict
Brushless motor technology is a genuine improvement, not marketing hype. The efficiency gains, longer battery runtime, reduced maintenance, and improved performance are real and measurable. For UK tradespeople using cordless tools every day, brushless is worth the premium on your primary tools — it’s an investment that pays for itself through longer battery life, less downtime, and tools that last longer.
But don’t feel you need to replace every brushed tool you own overnight. If your current brushed drill is working well, keep using it. When it’s time to replace it, go brushless. If you’re starting fresh or building a new platform, prioritise brushless for the tools you use most and save money on the rest.
The direction of the industry is clear — brushless is becoming the standard rather than the premium option, and prices are gradually closing the gap. Within a few years, brushed cordless tools will likely be limited to the budget end of the market. But right now, both technologies have their place, and the smart move is knowing which of your tools genuinely benefits from the upgrade.
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