How to Build a Brushless DC Motor?

Anyone can build your own brushless DC motors. Brushless DC electric motors are also named BLDC motors that are synchronous motors that are powered by a DC electric source via an integrated inverter/switching power supply. The controller of BLDC motor is easier to build and it has better torque characteristics than some other types.

Today, we will discuss how to build a simple brushless DC motor.


To build a motor right, you need to understand some basics of brushless DC motors. BLDC motor uses a rotating permanent magnet in the rotor, and stationary electrical current/coil magnets on the motor housing for the rotor, but the symmetrical opposite is also possible. A motor controller converts DC to AC.

How does a BLDC motor works?

Unlike brush DC Motor counterparts, the Brushless DC Motor does not contain any carbon brushes. Instead, the electromagnets within the motor remain stationary along with the armature, while the encased permanent magnets rotate, generating torque. The Brushless DC Motor is synchronous; both the stator and the magnetic field generate the same frequency, therefore avoiding any type of “slip” most induction motors exhibit.



Eddy current cause heat loose which essential take away from the possible output power of the motor. Typically professionally mode motors have laminations that are no more than half of a millimeter thick.


Motors can be made using any type of magnet, either that be the less powerful ferrite magnets or the more powerful neodymium magnets. To meet this demand neodymium arc magnets where used with an N50 rating.


Get number of windings you want.


It was preferable to do a thicker gauge wire so more current could flow at the cost of less turns. A wire gauge size 23 with a fussing current rating of 35A, which is more than will ever be put through the motor, was used.


The motor took a very long time to design, and the biggest factors that limited the motor were cost and how the motor would be machined. Just building a brushless DC motor out of house hold things isn’t very practical. Usually, we would suggest you buying one already assembled.

RC Hobby Mysteries: What is Brushless Motor?

Have you ever wondered what the mysteries of brushless motors are? How does it work? Why it becomes more and more popular though it was much more expensive than brushed motor? Well come with us on a voyage of discovery.

First, we need to learn about what’s brushed motor and brushless motor.

What’s brushed motor?
Brushed motor is also known as a brushed DC electric motor. It is an internally commutated electric motor designed to be run from a direct current power source. Brushed DC motors have been in commercial use since 1886. So it has a very long history. They can be varied in speed by changing the operating voltage or the strength of the magnetic field.

In a brushed motor, an electromagnet is mounted on a spinning arm, called an armature or rotor. The armature sits between two magnets set in a horseshoe configuration, collectively called the stator. When power is fed to the electromagnet, the arm moves, aligning the north and south poles of the electromagnet with the opposing poles of the stator.

What’s brushless motor?
So you may have a basic knowledge of brushed motor. Then we have a glance of brushless motor. Just as the name implies, there is no brush.

brushless DC motor

The brushless motor turns this design inside out. Magnets are placed on the armature and are surrounded by one or more electromagnets. The current switch is controlled by computer, turning electromagnets off and on by switching the current; the computer can also factor in the motor’s current speed to optimize efficiency, all without the need for brushes.

How it works?
A DC Brushless Motor uses a permanent magnet external rotor, three phases of driving coils, one or more Hall Effect devices to sense the position of the rotor, and the associated drive electronics. The coils are activated, one phase after the other, by the drive electronics as cued by the signals from the Hall effect sensors, they act as three-phase synchronous motors containing their own variable frequency drive electronics.

Brushless DC motors have been used in many applications, particularly devices such as computer hard drives, CD/DVD players and radio control models. Brushless motors are a popular motor choice for model aircraft including helicopters. Also, the brushless motor is also popular among remote control (RC) racing enthusiasts. As it boasts better performance and suffers less wear than brushed motors of similar size; they can provide a great amount of power to RC racers.

See also How to Build a Brushless DC Motor?

If you have any confuse of brushless motor, feel free to contact us.