In robotics and UAV (Unmanned Aerial Vehicle) applications, the motor is often referred to as the “heart” of the system. It directly determines the precision, agility, and efficiency of the equipment. Among the many motor types, coreless DC motors (also known as hollow cup motors) and brushed DC motors are the most common. This article compares their differences in structure, performance, and application, helping engineers and buyers understand which motor best suits their projects.
Shared foundation: Both are DC motors that convert electrical energy into mechanical energy through electromagnetic interaction.
Technological upgrade: The brushed DC motor is the traditional, widely used version. Coreless DC motors, however, are a structural upgrade designed for lightweight, fast-response, and high-efficiency applications—making them particularly suitable for robotics, drones, and medical devices.
Coreless DC Motor
Features a rotor without an iron core, designed in a hollow “cup-like” shape.
Advantages: Extremely lightweight, very low inertia (only 1/5–1/10 of iron-core motors), allowing millisecond-level acceleration and braking.
Limitations: Higher production complexity, limited power capacity, and more fragile winding structure.
Brushed DC Motor
The rotor uses an iron core with windings wrapped around it.
Advantages: Mature design, low cost, and wide power range.
Limitations: Heavy rotor with higher inertia, slower response time, and more energy loss due to eddy currents and iron core hysteresis.
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| Coreless Motor Structure | Brushed Motor Structure |
| Parameter | Coreless DC Motor | Brushed DC Motor |
|---|---|---|
| Response Speed | 5–10 ms (ultra-fast) | 200–300 ms |
| Efficiency | Up to 80–90% | Around 40–60% |
| Noise | Smooth and quiet | Higher due to iron core vibration |
| Service Life | Brushless-like longevity, thousands of hours | Brushes wear out, requires maintenance |
| Cost | High (complex process) | Low (mass production friendly) |
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| brushed dc coreless motor | Coreless dc motor with encoder cables |
Coreless DC Motors
Robotics: Used in humanoid robot joints, robotic hands, and high-precision gripping applications. Some advanced robots achieve positioning accuracy of ±0.1 mm thanks to coreless motors.
Drones / UAVs: Lightweight design improves flight endurance, while fast response ensures agile maneuvering.
Medical & Precision Instruments: Surgical robots, MRI positioning systems, and laboratory automation devices rely on coreless motors for accuracy and low-noise operation.
Brushed DC Motors
Consumer Electronics & Home Appliances: Electric toothbrushes, fans, and low-cost devices where affordability is critical.
Industrial Machinery: Conveyor belts, pumps, and equipment requiring continuous large-scale operation.
Transportation: Electric bicycles and certain EV components where torque output and robustness are prioritized.
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| Coreless motor in drones | Coreless motor in humanoid robot joints, robotic hands |
Coreless DC motors are the preferred choice for high-precision, lightweight, and responsive systems such as robots, drones, and medical devices. On the other hand, brushed DC motors remain the cost-effective workhorses in industrial and consumer applications where durability and higher power are needed.
Instead of replacing each other, the two types of DC motors complement one another—each thriving in its own application niche.
As a custom DC motor manufacturer, Lihua Motor specializes in designing and producing miniature DC motors ranging from 1V–36V, 0.05W–100W, with diameters from 5.4mm to 45mm. With over 20 years of production experience, 400+ employees, and 20,000+ customized solutions delivered, we provide tailored motor configurations for robotics, UAVs, medical equipment, and industrial applications—helping our partners stay competitive in the global market.
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