What and why to get a brushless cordless drill

Table of contents

Brushless drills are not just a trend.
Why use a brushless drill?
How does a brushless motor work exactly?
Parts of a cordless brushless drill
Brushless drills vs brushed drills
How do you replace the brushes on a brushed drill?
Should you get a brushless drill over a standard drill?
Reliability plays a big part when it comes to power tools.

6 min read and study time

Last updated on November 20, 2023 3:14 am

Brushless drills are not just a trend.

According to Aaron Barnett of BangingToolbox: Brushless drills are rapidly taking over the power tools market. They currently make up 30 – 50% of all cordless drills sold around the world. Brushless drills make use of a brushless motor, which is a step up from a conventional DC motor.

Brushless drills do away with carbon brushes, running more energy-efficiently and requiring less maintenance, due to the fact that there is no need to replace the brushes.

Brushless design allows for smaller and lighter drills with even more power.

So, what else makes brushless drills better than brushed ones? Let’s find out and drill down the details.

Why use a brushless drill?

Added power. Brushless motors are capable of achieving higher RPMs than standard ones. Performance is significantly increased as there are no longer brushes that touch the rotor and slow it down due to the added friction.
Higher energy-efficiency. The design of brushless motors is centered on reducing friction, allowing you to fully maximize available power. Modern brushless drills are less intensive on their battery use since the motors actually adjust consumption based on how much resistance the drill encounters when working. This means that drilling through lighter materials, such as drywall and styrofoam, doesn’t use up 100% of the current battery. You’d have plenty of power for installing brackets or frames after other drilling jobs such as installing your bike or simply drilling holes.
Less maintenance. Conventional DC motors need to have their brushes replaced to remain operational. Regular use eventually wears down the brushes due to all the friction. Brushless drills eliminate this problem and are naturally suited for longer-term use without maintenance.

How does a brushless motor work exactly?

What is a brushless drill and how does it work? Both brushed and brushless motor assemblies consist of two main components: a stator and a rotor.

Unlike a brushed motor, brushless ones have permanent magnets [1] on the rotor and copper windings on their stator.

These motors alternate the polarity of the windings found in their interior to make the rotor spin.

A computer control chip and hall effect sensor inside the motor then creates a closed-loop so that the motor knows exactly how fast it’s spinning.

This innovative design makes brushless motors more intuitive and durable than standard DC ones.

Parts of a cordless brushless drill

Wondering what is a brushless cordless drill made of? Here are the parts of a cordless drill:

Chuck. The chuck assembly is the mechanism that holds detachable drill bits and other accessories by locking them into place. All cordless drills have three-clawed chucks that hold standard-sized bits.
Brushless Motor. What is a brushless drill motor, you ask? At the heart of a brushless drill is a brushless motor. This is the main factor that goes into the cost of these drills as they function as the tool’s highly sustainable and highly capable heart.
Torque Control. Torque becomes highly crucial when drilling. The best brushless drills have a torque control setting behind the chuck that allows you to select and regulate the needed turning force.
Gear Selector Switch. Most modern drills can select from different speed ranges by changing gears to make them suitable for a wide range of tasks. In other tools, this is sometimes referred to as “variable speed control”.
Speed Control Trigger. This determines how fast the drill head rotates based on how hard you press on the trigger. It’s a quick and easy way to adjust how much power is released. Release fully to stop drilling; a useful safety feature.
Direction Switch. Usually located above the speed control trigger, this switches the direction of the drill between clockwise and counterclockwise. Clockwise drilling is used for driving screws, while counterclockwise drilling is used for removing them or for backing the drill out.

Grip. Grips should be ergonomic to reduce strain on your hands when in use. Grips usually have a textured rubber surface and allow you to maintain a first class grip even if your hands get wet or moist.
Battery. Cordless brushless drills, much like their cordless brushed cousins, still require batteries. They usually have batteries with 12 – 18v capacities, though they can last up to 30% longer compared to a brushed drill with the same battery size.
LED light. An added utility that allows you to work in poorly lit corners. Most cordless drills and impact drivers have a white LED light that turns on automatically when you pull the trigger.

Brushless drills vs brushed drills

Over traditional brushed drills, the added efficiency and durability of brushless drills simply make them superior. This isn’t to say that you shouldn’t get a brushed drill at all, but take look at a what brushless drills offer:

Advantages

Longer lifespan due to the absence of carbon brushes.
Longer up-time due to computer-assisted power consumption.
A low-friction motor produces higher RPMs.
Lower friction reduces heat build-up even in prolonged use.
The motor design allows for smaller and lighter models without compromising output.

Disadvantages

Difficult and more expensive to repair.
They are more expensive, costing 30% more to manufacture and even greater to purchase.

When is time to replace a drill’s brushes?

If you are still using a brushed drill, keep an eye out for the following symptoms as they are signs that it might be time to replace your brushes:

Your drill needs some shaking just to start.
Your drill no longer reaches up to its max RPM.
Your drill heats up more quickly.
When your drill emits a burning smell when in use.
Sparks occasionally form on the commutator which can easily be seen through the drill’s cooling vents.

How do you replace the brushes on a brushed drill?

Unscrew the drill casing. Remove the back panel until you expose the commutator and carbon brushes.
Each brush is ‘clipped’ in place and maintains contact with the commutator via a spring. Remove the brushes by removing the clips and easing off the spring with a small screwdriver. The brushes will then slide out.
Slide in the new brush and secure it in place by easing back the spring. Lock in place using the contact clip.
Do the same with the second brush.
Place back the casing and screw shut.

Who made the first brushless drill?

So who made the first brushless motor in a drill?

Makita first experimented with the idea of slapping brushless motors into their power tools in 2003 [2]. They started releasing brushless drills commercially with their brushless impact driver in 2009.

It was from then on those other manufacturers, such as DeWalt and Milwaukee, followed suit by creating their own line of brushless drills and other power tools.

The shift to brushless motors resulted in the emergence of more intuitive power tools, with some even able to remember optimal power and speed settings for specific applications. Such is the case of Milwaukee’s One-Key smart tools.

Should you get a brushless drill over a standard drill?

Choosing whether or not to buy a brushless drill depends on personal preference as well as situational needs. Those working on a budget might have a hard time acquiring one of these as they are more expensive, but the benefits greatly outweigh the costs so it’s actually wiser to invest in one for the long-term.

Speaking of length, since brushless drills are made to last and operate longer, beginners, casual DIYers, and even professionals can all take advantage of the tool’s numerous merits.

Who makes the best brushless drills?

1. Makita

Founded in 1915, Makita has been producing top-quality tools for over 100 years.

With their experience and renown, it’s not surprising how this brand came to be known globally as one of the greatest when it comes to commercial tools manufacturing.

Since Makita pioneered the brushless drill, it’s safe to say that they have the best money can buy.

2. DeWalt

DeWalt was founded in 1920 and is credited for perfecting the design of the 1st woodworking machine.

For most, DeWalt is the American counterpart of Makita, producing power tools whose quality rivals that of the Japanese tool giant.

3. Milwaukee

Stepping in on the scene in 1924, Milwaukee Tool has since led the industry in the development of innovative solutions for increased tool productivity and durability.

Catering more to the masses of professional electrical workers, Milwaukee chucks out a wide range of reliable and affordable tools; brushless drills included.

Reliability plays a big part when it comes to power tools.

Brushless motors ensure that you can always count on your drill whenever you need it.

Not only does it do away with the nuisance and limitations of carbon brushes, but it also does a one-up on conventional drills by giving you a smaller and lighter tool that packs a bigger punch.

While brushless drills may not be for everybody due to their significantly higher price, investing in one is definitely a practical move to make – it’s a decision that’s almost as intuitive as brushless motors.