The main difference between brushed DC motors and brushless DC (BLDC) motors lies in how they switch current (commutation), which affects efficiency, lifespan, cost, and maintenance.

Design
• Brushed Motors: Use carbon brushes and a commutator for mechanical switching; simple and directly powered by DC
• Brushless Motors: Use electronic controllers (ESC) with no brushes; more advanced design

Performance & Efficiency
• Brushed: Lower efficiency due to friction and heat losses
• Brushless: Higher efficiency and better performance (typically 10–20% more efficient)

Maintenance & Lifespan
• Brushed: Brushes wear out → requires maintenance; shorter lifespan
• Brushless: No wear parts → minimal maintenance; longer lifespan

Heat & Noise
• Brushed: More heat and noise due to friction and sparking
• Brushless: Runs cooler and quieter

Cost & Control
• Brushed: Lower cost, simple control (voltage-based)
• Brushless: Higher cost, requires controller but offers precise speed and torque control

Applications
• Brushed: Tilt/trim motors, starter motors, basic automotive systems
• Brushless: Electric vehicles, drones, robotics, high-efficiency tools

Conclusion
Brushed motors are ideal for simple, cost-effective applications, while brushless motors are better for high efficiency, durability, and precision performance.