The Rise of Brushless Power Tools: Why Cordless, Lithium, and Rechargeable are the Future

The Rise of Brushless Power Tools: Why Cordless, Lithium, and Rechargeable are the Future

The Current Situation of Cordless Power Tools

Cordless power tools have transformed the way both professionals and DIYers work, with brushless power tools at the forefront of this evolution. Over the past five years, the adoption of brushless cordless tools has accelerated sharply. Once positioned as a premium option, the cost gap between brushless and brushed models has narrowed to just 10–15% in many mid-range categories, making them accessible to a wider audience.

Powered by lithium-ion rechargeable batteries, today’s cordless brushless tools offer higher efficiency, longer runtimes, and more compact designs. Manufacturers are introducing brushless versions across nearly all categories—drills, impact wrenches, circular saws, angle grinders, and garden tools—reshaping the global tool market.

Advantages of Brushless Power Tools

The benefits of brushless technology are proven in both engineering and field tests:

• Longer lifespan – No carbon brushes means less mechanical wear. Independent tests show brushless motors can last up to 50% longer than brushed equivalents under identical workloads.

• Higher power & torque – Eliminating brush friction improves energy transfer. A 20V brushless drill can deliver 15–30% more torque, drilling faster into hardwood, steel, and masonry.

• Greater efficiency & runtime – With 85–90% efficiency versus 75–80% for brushed, brushless tools can extend battery life by 25–50%. For example, a brushed driver may sink 150 screws per charge, while a brushless version can exceed 200.

• Durability under load – Brushless grinders run 10–15°C cooler under heavy use, reducing component stress and extending tool life.

• Eco-friendly performance – A jobsite switching 50% of tools to brushless could cut annual battery charging power use by 20–30%, lowering operational carbon output.

• Compact versatility – Smaller, lighter motors enable 12V brushless tools to match the torque of older 18V brushed models, ideal for tight spaces.

Why Some Mature Markets Lag Behind？

In markets like Germany, brushless tool adoption trails faster-growing regions. Key reasons include:

• Conservative buying habits – Professionals often stick to trusted brushed models, such as Bosch Professional SDS drills, that have served reliably for years.

• Long replacement cycles – Industrial tools may remain in service for 8–10 years, delaying upgrades.

• Lingering price perceptions – Some buyers still view brushless as “premium” despite smaller price gaps.

• Service familiarity – Repair technicians are more accustomed to maintaining brushed motors and may lack training for brushless repairs.

• Market maturity paradox – In established markets, buyers are more cautious due to saturated competition, unlike emerging markets where upgrading aligns with market excitement.

Example: A Munich construction firm may continue purchasing brushed SDS drills to match existing spare parts and chargers, even if brushless models cost only 10% more and offer longer runtimes.

Brushless Is the Must-Follow Trend

The move toward brushless cordless tools is an industry-wide shift driven by measurable market forces:

1) Sales Growth Momentum

• The global brushless DC motor market reached USD 17.8 billion in 2023 and is projected to grow at a 6.9% CAGR through 2030 (Grand View Research), with cordless tools as a major driver.

• In North America, brushless tools grew from 15% of cordless sales in 2017 to 35–40% in 2022, exceeding 70% penetration in premium drills and impact drivers.

2) Price Gap Closing

• In 2018, brushless drills cost 30–40% more than brushed. Today, in many cases, that gap is down to 10–15%, due to improved manufacturing efficiency, lower rare-earth magnet costs, and optimized motor production lines.

3) Consumer Preference Shift

• UK and US retailer surveys show 65%+ of professionals prefer brushless tools for replacements, citing runtime, power, and reduced maintenance.

• DIY buyers increasingly equate “brushless” with premium quality, influencing purchase decisions.

4) Battery Technology Synergy

• Lithium-ion platforms (20V, 40V, 60V) match perfectly with brushless motors, which can use each watt-hour more effectively. Energy efficiency gains of up to 25% extend runtimes without larger battery packs.

5) Competitive Positioning

• Brands like Makita, Milwaukee, and DeWalt are shifting entire lines to brushless in premium and pro-grade tools.

• Budget players are launching sub-$100 brushless kits, speeding mainstream adoption.

6) Sustainability Advantage

• Higher efficiency and longer service life mean fewer tools in landfills and lower lifetime energy usage, aligning with green building certifications and sustainability targets.

How to Conquer the Brushless Tool Market

Technical Readiness

• Develop modular brushless motor platforms compatible with multiple voltages (12V, 20V, 40V) for easier scaling.

• Use smart electronic controls for load-sensitive torque and speed adjustments.

• Invest in advanced battery management systems (BMS) to enhance lithium-ion pack safety, performance, and cycle life.

Pricing Strategy

• Secure long-term supply agreements for neodymium magnets, MOSFETs, and stators to stabilize material costs.

• Expand in-house motor production to reduce supplier dependency.

• Offer entry-level brushless kits priced within 5–10% of brushed models to encourage upgrades.

Market Education

• Use side-by-side demos in stores and online (e.g., brushed vs. brushless drill driving 100+ screws per charge).

• Provide extended warranties to reduce buyer hesitation.

Example: A brand entering Eastern Europe could launch a 20V brushless drill kit at $99, paired with promotional tests showing 30% longer runtime than brushed equivalents.

Liangye’s Brushless Power Tool Vision

Liangye delivers a full range of cordless brushless power tools, from handheld drills, wrenches, angle grinders, and saws to garden equipment like lawn mowers, leaf blowers, and pruners. With multi-voltage lithium-ion platforms and continuous R&D, Liangye is positioned to lead the next stage of global tool innovation.

The future is clear: brushless, cordless, and rechargeable tools will dominate workshops and gardens worldwide — and Liangye is set to be one of the driving forces behind this transformation.