Brushed DC Motor Market By Motor Type (Permanent Magnet, Series, Shunt, Compound); By Voltage (12V, 24V, 48V & Above); By Application (Automotive, Industrial Equipment, HVAC, Household Appliances, Robotics & Toys); By End User (OEMs, Aftermarket & Repair Networks); By Geography, Segment Revenue Estimation, Forecast, 2024–2030

1. Introduction and Strategic Context

The Global Brushed DC Motor Market is projected to grow at a CAGR of 5.8% , valued at approximately USD 9.6 billion in 2024 , and expected to reach around USD 13.5 billion by 2030 , as per Strategic Market Research’s inte rnal .

 

Brushed DC motors remain one of the most widely used motor types globally, even in the face of rising brushless alternatives. What keeps them relevant? Simplicity, cost-effectiveness, and a mature ecosystem that’s hard to beat in certain settings. For OEMs and systems integrators who prioritize torque control, ruggedness, and easy speed modulation — particularly in low-voltage environments — brushed motors are still the first call.

 

Their strongest foothold? Automotive systems like power windows, wipers, HVAC blowers, and adjustable seating. Add to that the household appliances space — vacuum cleaners, toys, mixers, and small fans. Despite EVs moving toward brushless technologies, legacy vehicles and hybrid platforms still rely on brushed motors for auxiliary functions. And in industrial automation , especially in cost-sensitive economies, brushed motors are being deployed for conveyor belts, labeling machines, and portable tools.

 

From a manufacturing standpoint, brushed motors benefit from stable supply chains. The raw material needs — copper, steel, carbon brushes — are well-established, which keeps production costs predictable. Emerging suppliers in India, China, and Eastern Europe are now catering to both global and domestic demand at scale, which has increased price competition in the 12V and 24V segments.

 

Government policies also play a quiet but meaningful role. While brushed motors aren't the centerpiece of energy efficiency legislation, their use in low-duty or intermittent-load applications often falls below regulatory thresholds. That’s a strategic advantage in segments like medical mobility aids, small industrial robots, or HVAC damper actuators where cost and compliance must strike a balance.

 

There’s another angle worth noting: aftermarket economics . These motors are frequently sold as replacements — not just components in a product. Distributors and repair networks worldwide carry hundreds of brushed DC SKUs for fans, power tools, and automation panels. This non-OEM channel accounts for a significant chunk of recurring revenue, especially in emerging markets.

 

Key players in this market include Johnson Electric, Mabuchi Motor, Nidec Corporation, Maxon , and AMETEK , along with a long tail of regional manufacturers in Asia and Eastern Europe. Their stakeholders span across OEM product designers, appliance brands, automotive Tier 1s, repair networks, and private-label brands sourcing motors for white goods and small devices.

 

So, while brushed motors don’t make headlines the way brushless or stepper motors do, they occupy a crucial volume-driven role in motion systems. And that role isn’t shrinking — it’s shifting toward smarter manufacturing, broader customization, and deeper integration into connected products.

 

2. Market Segmentation and Forecast Scope

The brushed DC motor market is structured across multiple dimensions — reflecting differences in voltage requirements, motor configuration, target applications, and regional use cases. Below is the segmentation framework used in this forecast, along with a look at the fastest-moving segments.

By Motor Type

• Permanent Magnet (PMDC) Motors These dominate volume sales, especially in automotive and consumer electronics. They’re known for simple design and strong torque at low speeds.

• Series Motors Used where high starting torque is critical — like in power tools, industrial cranes, or elevators.

• Shunt Motors Offer stable speed and are preferred in lab and HVAC fans where load fluctuations are minimal.

• Compound Motors Hybrid configurations used in industrial settings that need both torque and speed stability.

Permanent magnet motors account for nearly 62% of market share in 2024 due to their broad application base and efficiency in compact form factors.

By Voltage

• 12V Standard for automotive and consumer electronics. Ideal for portable tools and battery-powered equipment.

• 24V Common in commercial-grade cleaning machines, small AGVs, and mobility scooters.

• 48V and Above Targets industrial and commercial HVAC systems, conveyor belts, and robotics.

The 24V segment is growing fastest — as mid-power automation and smart factory tools become more cost-accessible.

By Application

• Automotive Systems Includes power seats, windshield wipers, air vents, and door locks.

• Industrial Equipment Light-duty conveyors, packaging systems, labeling machines.

• Household Appliances Mixers, coffee machines, vacuum motors, and small fans.

• HVAC Systems Used in damper actuators, exhaust systems, and portable units.

• Robotics & Toys A growing niche, especially in consumer-grade robotics and smart learning toys.

Automotive remains the top revenue contributor, but industrial automation and HVAC are catching up, particularly with regional manufacturing growth.

By End User

• OEMs (Original Equipment Manufacturers ) Account for bulk procurement for product integration — from vacuum manufacturers to HVAC brands.

• Aftermarket & Repair Networks Especially strong in Asia and Latin America. Sales come from spare motor units for tools, fans, and replacement kits.

OEMs make up around 70% of total motor demand, but aftermarket players are increasingly relevant in price-sensitive and mature product categories.

By Region

• Asia-Pacific Dominates production and consumption. China and India together account for more than half the global brushed DC motor units sold.

• North America Still strong in automation and HVAC demand. Also a large buyer of premium and custom motors.

• Europe Favors compact and energy-efficient designs. Significant use in small kitchen appliances and building automation.

• Latin America & Middle East/Africa (LAMEA ) Emerging demand driven by household appliance penetration and aftermarket supply chains.

Scope Note : Although brushed DC motors appear commodity-like, customization by voltage and motor topology is becoming more common. OEMs are increasingly specifying motor control response, brush life cycles, and housing material — turning what used to be off-the-shelf products into semi-tailored solutions.

 

3. Market Trends and Innovation Landscape

Brushed DC motors may seem like a legacy product, but under the surface, there’s real innovation happening — especially as manufacturers try to squeeze more performance, life span, and cost-efficiency out of a mature platform. Here's how the space is evolving.

Longer Brush Life, Smarter Brushes

The biggest pain point in brushed motors? Wear and tear. But that’s slowly changing. Manufacturers are redesigning brush assemblies with advanced carbon composites, flexible spring tensions, and copper-infused materials that reduce heat buildup.

One mid-sized European OEM claims their latest PMDC motors now last 30% longer in continuous HVAC use, just from a redesigned brush holder and air channeling.

On the factory floor, several suppliers are also integrating automated brush alignment systems — improving motor balance and cutting rejection rates in high-speed assembly lines.

Modular Designs for Custom Torque Curves

Traditionally, brushed motors were black-box components. But now, modular designs are enabling engineers to swap out armature windings, casing materials, and gear interfaces with more flexibility.

This is especially true in automotive seating systems and battery-powered lawn tools , where OEMs want unique torque-speed profiles without commissioning entirely new motor SKUs. It’s also catching on in low-cost robotics , where mass customization matters more than raw specs.

Integration with Embedded Controllers

Even the humblest brushed motors are getting smarter. Vendors are bundling embedded H-bridge controllers or PWM input boards directly into motor casings. The result? Drop-in motors that talk to IoT platforms or factory automation systems without needing a separate controller.

This trend is most visible in:

• Smart HVAC dampers with feedback loops

• Precision motorized locks and actuators

• DIY robotics kits for education and prototyping

And as low-cost microcontroller units (MCUs) become easier to embed, brushed motors are getting packaged with real-time diagnostics: overheat protection, fault detection, and dynamic speed throttling.

Noise Suppression and EMI Control

One overlooked innovation? Quieter motors. As more DC motors end up in consumer products , vendors are investing in design changes to reduce electrical noise and electromagnetic interference.

Ferrite shielding, noise-dampening mounts, and soft-start logic are now becoming standard, especially for motors targeting:

• Medical devices (like mobile carts and patient lifts)

• Premium home appliances (coffee makers, blenders)

• Mobility aids and electric wheelchairs

In fact, one Korean appliance brand has quietly replaced all their brushed motor SKUs with low-noise variants that comply with stricter EU EMI limits.

Sustainability Through Recycling and Repairability

There’s growing pressure — especially in Europe — to make brushed motors more serviceable. Some manufacturers are launching “open-access” motor designs with easily replaceable brushes, armatures, and housing caps. This is partly a response to Right to Repair laws and also a nod to the rising resale/refurbishment ecosystem for appliances and tools.

Motor recycling programs are also becoming a niche B2B service, especially for industrial users who deal with large volumes of retired units.

AI Meets Old Tech? Kind Of.

While AI isn’t transforming brushed DC motors directly, it’s quietly improving how they’re selected and deployed. Some motion planning software now includes brushed motor simulation modules — helping engineers optimize motor selection digitally before prototyping.

This matters most in contract manufacturing, where switching to a brushed unit (instead of a stepper or brushless) can cut costs dramatically — if it still meets the torque profile.

 

4. Competitive Intelligence and Benchmarking

Despite being a relatively commoditized segment, the brushed DC motor market is shaped by a handful of key manufacturers who are quietly influencing pricing, innovation, and geographic expansion. What separates leaders from followers here isn’t always tech — it’s reliability, volume agility, and how deep their OEM relationships run.

Johnson Electric

This Hong Kong-headquartered giant is the most vertically integrated brushed motor supplier on the planet. They’ve built long-term supply relationships with top automotive Tier 1s and white goods brands across Europe and the U.S.

Their real edge? Scale. They produce millions of units per month across various brush types, gear assemblies, and voltages — often delivering directly to assembly lines.

They’re also doubling down on automated manufacturing in Mexico and Vietnam to reduce labor dependency and respond faster to demand from North America and ASEAN regions.

Mabuchi Motor

Japan-based Mabuchi specializes in small-format DC motors — especially in toys, personal care products , and automotive in-cabin features like mirrors, vents, and sunshades.

Their differentiation lies in consistent quality across high volumes. They’re also expanding into high-performance variants for electric bike assist systems and compact robotics, particularly in China and South Korea.

They’re quietly investing in R&D to extend brush life for motors used in continuous rotation applications — a move aimed at wear-heavy markets like power tools.

Nidec Corporation

Known globally for their brushless motor dominance, Nidec still retains a significant brushed portfolio — especially in HVAC and commercial appliance use cases.

They often lead when it comes to compactness and noise control , which makes them the go-to for medical carts, embedded cooling systems, and premium fans .

Nidec’s brushed motors are typically found in applications where space constraints meet moderate duty cycles , and they’ve been marketing their units with integrated EMI shielding and vibration dampers.

AMETEK

This U.S.-based player has carved out a niche in aerospace-grade and ruggedized brushed motors , targeting everything from lab automation gear to defense robotics .

They’re not a high-volume manufacturer, but their motors are used where failure isn’t an option. That includes industrial analyzers, small pump drives, and thermal management systems in critical environments.

They also offer brushed motors with integrated tachometers and encoders — ideal for motion control systems that can’t accommodate external sensors.

Maxon

Maxon focuses on precision-engineered brushed DC motors — typically for medical devices , robotic prosthetics , and aerospace systems . Their brushed lineup is less about price and more about control fidelity and signal integrity .

Their latest brushed motor generation includes low-cogging torque variants with extended brush life and extremely tight voltage tolerances.

Maxon also serves a growing base of university research labs and R&D-focused integrators , especially in the U.S. and Western Europe.

FAULHABER

Smaller in volume but highly respected, FAULHABER is known for miniature brushed motors with coreless designs . These are widely used in microsurgery tools, lab automation equipment , and optics systems .

Their brushed offerings are typically priced at a premium, but their precision and build quality often justify the cost — particularly in applications with no margin for vibration or EMI.

Competitive Summary

Company	Focus	Differentiator
Johnson Electric	Automotive, Appliances	Scale + automated manufacturing
Mabuchi Motor	Toys, In-cabin automotive	Quality at volume
Nidec	HVAC, Premium fans	Noise control, compact design
AMETEK	Aerospace, Industrial	Ruggedization and sensors
Maxon	Medical, Robotics	High-precision performance
FAULHABER	Micro devices	Coreless miniaturization

 

5. Regional Landscape and Adoption Outlook

The brushed DC motor market is global by nature, but adoption patterns look quite different depending on the region. Cost tolerance, industrial maturity, energy regulation, and even climate play a role in how and where these motors are used. Let’s unpack the current landscape.

Asia-Pacific (APAC)

APAC leads the world in brushed DC motor volume production and consumption — thanks largely to China, India, and Southeast Asia .

In China , brushed motors are still widely used in low-voltage consumer appliances, electric scooters, and toys. Domestic manufacturers dominate this segment, offering millions of units at ultra-competitive prices. Shenzhen and Guangzhou are hotspots for brushed motor exports.

India , meanwhile, is driving demand through the rise of small-scale automation , portable tools , and battery-powered sprayers in agriculture. Aftermarket repair shops, too, create steady pull for 12V and 24V motors in cities and rural clusters alike.

Also notable: Vietnam and Thailand are becoming key sourcing hubs for Japanese and Korean OEMs, as they look to diversify away from China.

North America

Here, brushed DC motors remain essential in:

• HVAC systems (blower motors, damper actuators)

• Commercial cleaning equipment

• Medical mobility devices

• Industrial tools and conveyors

While brushless motors are gaining traction, many North American OEMs still specify brushed units where simplicity, cost, and direct drive compatibility are more critical than extended lifecycle or efficiency.

There’s also growth in hobbyist robotics , home improvement tools , and replacement motors via online B2B distribution platforms.

In the U.S. and Canada, energy standards and noise regulations are nudging suppliers to upgrade EMI shielding and thermal safety features.

Europe

Europe leans toward quality and sustainability — which puts pressure on brushed motor suppliers to provide:

• Lower-noise units for residential appliances

• Longer-lasting brushes with recyclable components

• CE-compliant motors for embedded applications

Markets like Germany and the Nordics are actively phasing out brushed motors in new industrial projects, but existing equipment still drives healthy replacement demand.

Italy and Eastern Europe , on the other hand, show sustained brushed motor use in manufacturing lines, commercial HVAC, and power tools — especially in mid-sized factories and workshops.

Repairability and spare part availability also carry more weight in EU purchase decisions, particularly in light of Right to Repair directives.

Latin America, Middle East & Africa (LAMEA)

This is the most price-sensitive and aftermarket-driven region for brushed motors.

In Brazil, Mexico, and South Africa , demand is coming from:

• Household appliances (mixers, fans, drills)

• Automotive repair networks

• Mobile agricultural tools

Large volumes are imported from China and repackaged or rebranded for regional use. That said, local assembly plants are starting to emerge, especially in Mexico and Egypt.

In Gulf countries , brushed motors are commonly used in commercial HVAC , but the shift to higher-efficiency systems may limit growth over time.

Sub-Saharan Africa relies on brushed motors for off-grid applications , like solar-powered pumps and mobile refrigeration. These are areas where brushed simplicity — even at the cost of shorter life — is still preferable to higher-spec alternatives.

Regional Snapshot

Region	Maturity	Key Growth Drivers
Asia-Pacific	High	Mass production, small motor demand, industrial tools
North America	Medium	HVAC, medical mobility, aftermarket tools
Europe	Medium-High	Sustainability, quality, precision appliances
LAMEA	Low-Medium	Cost-driven aftermarket, agri-tools, home devices

Regional success isn’t about dumping volume — it’s about matching motor specs to local needs. In APAC, that means lean price points. In Europe, it’s about lifetime value. In North America, it’s about application flexibility.

 

6. End-User Dynamics and Use Case

The brushed DC motor market may appear component-driven on the surface, but under the hood, it’s driven by a wide mix of end users — each with distinct expectations around price, performance, customization, and durability. Let’s break down who’s using these motors and how they’re integrating them into real-world systems.

OEMs (Original Equipment Manufacturers)

These are the primary buyers, especially in automotive , appliance , and HVAC sectors. Their procurement teams prioritize:

• Form factor adaptability — Can the motor fit in tight design specs?

• Reliability under variable duty cycles

• Repeatable sourcing from Tier-1 suppliers or regional manufacturers

Many OEMs operate with tight unit economics, especially in consumer electronics and compact appliances. In these segments, brushed motors hit the right balance of cost vs. control — making them an obvious choice for applications like hand dryers, electric toothbrushes, or car door actuators.

Also, OEMs are increasingly asking for partial customization : different shaft types, embedded sensors, or thermal cutoffs. This makes modular brushed motors more appealing.

Aftermarket and Repair Networks

In Latin America, Southeast Asia, and parts of Eastern Europe, the aftermarket is a major buyer of brushed DC motors. These are typically:

• Replacement motors for fans, vacuums, and hand tools

• Repair kits for small robotics and hobbyist builds

• Motors bundled in reseller kits for regional brands

The key here is availability and standardization — not performance. A distributor in São Paulo might sell the same 24V brushed unit for a pressure washer, a mobility scooter, and an electric fan.

Interestingly, many brush-type motors used in the field today outlast their expected life thanks to third-party repair services that replace brushes, rewind coils, or retrofit mountings.

Small and Medium Enterprises (SMEs)

SMEs in manufacturing, packaging, agriculture, and HVAC service often purchase brushed motors for retrofitting older systems or scaling up low-tech automation.

They value motors that are:

• Easy to replace with minimal tools

• Compatible with legacy control systems

• Cheap enough to stock in bulk

A small HVAC installer, for example, may keep half a dozen brushed motors in the van to replace broken actuators or vent drives on the spot — no calibration needed.

Educational, DIY, and Hobbyist Communities

This is a growing but often underestimated segment. Brushed DC motors are the go-to choice in:

• STEM education kits

• DIY robotics

• 3D printer accessories

• Battery-powered toys

Low-voltage motors (6V–12V) are ideal for students and hobbyists experimenting with automation. These users value brushed motors not for longevity, but for tinkerability . They want something that can be easily driven by Arduino boards, modded , or swapped without soldering.

Several Asian brands now ship brushed motor kits with mount brackets, gears, and driver boards — specifically targeting this segment.

Use Case Highlight

A mid-sized HVAC maintenance company in Dallas noticed increasing service calls for legacy ventilation systems in commercial buildings. These systems used 24V brushed DC motors to actuate dampers — many of which had begun to fail after 8–10 years of service.

Rather than push full system replacements, the company began sourcing high-efficiency brushed replacements with noise suppression and auto-stop sensors . The motors were sourced from a supplier in Taiwan and pre-wired with JST connectors.

Within 12 months, the service team cut average repair time by 30%, increased customer retention, and built a small inventory-based resale channel for other contractors in the area.

This illustrates how even in mature markets, brushed motors can unlock value — not by being cutting-edge, but by being serviceable, accessible, and application-specific.

 

7. Recent Developments + Opportunities & Restraints

While brushed DC motors aren’t the flashiest segment in the motion control ecosystem, there’s been a steady wave of product tweaks, ecosystem upgrades, and strategic moves that are reshaping how — and where — they’re used. Let’s take a look at recent activity across the industry, followed by core opportunities and constraints.

Recent Developments (Last 2 Years)

1. Johnson Electric expanded its manufacturing footprint in Vietnam (2023) In response to rising U.S. and EU demand for non-China sourcing, the company launched a new production line focused on 12V brushed motors for automotive seat adjustment and HVAC blowers. The move is designed to shorten lead times and offer duty-free routing to North American clients.

2. Mabuchi Motor introduced a compact brushed motor platform for electric toothbrushes (2024 ) Built on a new high-density winding system, the motor delivers smoother startup torque and reduced vibration. Designed specifically for high-volume personal care OEMs in China and Southeast Asia.

3. Nidec launched a noise-dampened brushed motor series for compact HVAC systems (2023 ) These motors are being integrated into portable air purifiers and dehumidifiers — targeting EU and U.S. markets with strict residential noise standards.

4. AMETEK partnered with a U.S. defense contractor to deliver rugged brushed motors for field-grade robotics (2024 ) This limited-run series features waterproof casings, extended brush life, and integrated tachometers — built for harsh, mobile environments.

5. FAULHABER announced a recyclable brushed coreless motor line (2023) In a push for circular design, FAULHABER unveiled miniature brushed motors that are easier to disassemble and recycle — starting with its European customer base.

Opportunities

1. Retrofit and Aftermarket Growth in Emerging Markets Countries like India, Indonesia, Brazil, and Turkey still run large volumes of brushed motors in appliances and light machinery. As the used equipment market matures, so does the need for quality replacement motors — especially in the 12V–48V range.

2. Custom Motor Platforms for Niche Robotics and Mobility Tools As modular robotics and assistive mobility grow, brushed motors are being deployed for fine torque control in exosuits , micro-AGVs, and educational robots — all of which value easy-to-integrate, cost-efficient motor units.

3. Recyclable Designs for EU Markets Driven by stricter EU regulations and eco-labelling standards, there’s a small but growing push toward repairable and recyclable brushed motors. Suppliers that offer easy brush replacement, disassembly guides, and recyclable packaging could win mid-size appliance OEMs looking to green their supply chain.

Restraints

1. Limited Lifecycle Compared to Brushless Alternatives As brushless motors drop in price and integrate better with compact controllers, brushed motors face lifecycle scrutiny — especially in continuous-duty applications. For high-performance robotics and energy-sensitive appliances, brushed designs are still seen as second-tier.

2. Shrinking Margins and Price Compression In core markets like HVAC, automotive accessories, and consumer appliances, brushed DC motors are under massive pricing pressure. Chinese suppliers, in particular, have pushed commoditization to the point where many brands compete solely on cents-per-unit — leaving little room for quality improvements or R&D investment.

 

7.1. Report Coverage Table

Report Attribute	Details
Forecast Period	2024 – 2030
Market Size Value in 2024	USD 9.6 Billion
Revenue Forecast in 2030	USD 13.5 Billion
Overall Growth Rate	CAGR of 5.8% (2024 – 2030)
Base Year for Estimation	2023
Historical Data	2019 – 2023
Unit	USD Million, CAGR (2024 – 2030)
Segmentation	By Motor Type, Voltage, Application, End User, Geography
By Motor Type	Permanent Magnet, Series, Shunt, Compound
By Voltage	12V, 24V, 48V & Above
By Application	Automotive, Industrial Equipment, HVAC, Household Appliances, Robotics & Toys
By End User	OEMs, Aftermarket & Repair Networks
By Region	North America, Europe, Asia-Pacific, Latin America, Middle East & Africa
Country Scope	U.S., China, India, Japan, Germany, Brazil, Mexico, South Korea, etc.
Market Drivers	- High demand for cost-effective motion systems - Large aftermarket replacement cycles - Advancements in modular and recyclable brushed designs
Customization Option	Available upon request