Brushless vs Brushed Motors in Airsoft

Airsoft enthusiasts are constantly seeking ways to improve performance, and one of the most significant advancements in recent years for AEG replicas has been the adoption of brushless motors. This article will explore the differences between brushless and brushed motors, their impact on performance, and why you might want to consider upgrading your replica to a brushless motor too.

Key Differences and Benefits

Brushless motors differ from traditional brushed motors in their design and operation. In a brushless motor, the electromagnets are stationary, while the permanent magnets rotate. This configuration eliminates the need for physical brushes to transfer electricity, resulting in several key benefits for airsoft guns.

Another major difference between brushed and brushless motors is how they are powered. In the case of a brushed motor, you can just directly hook up a battery to the motor terminals and it will just go full speed. However, brushless motors are built differently and they normally have 3 or more motor terminals.

To use brushless motors in airsoft replicas, manufacturers had to integrate an electronic speed controller (ESC), which rapidly switches polarity between the three connectors within the motor housing, a challenge that initially hindered the technology's affordability and adoption.

Improved Battery Life

The main benefit for brushless motors is that they are significantly more efficient than their brushed counterparts. On average brushless motors are 2-3x more efficient than regular brushed motors. This efficiency translates to significantly longer battery life, players can focus on the game without worrying about running out of power, even during longer matches or intense firefights.

We did a side-by-side comparison on our SSR4 Gen2 and compared the stock Novritsch 30K brushed motor vs the Solink Advanced 31K brushless motor. We used a  ToolkitRC WM150 Watt Meter to measure the power consumption differences and these were the results:

brushed motor consumed up to 27.4A with estimated ~40mAh consumption per shot

brushless motor consumed up to 11.5A with estimated ~6mAh consumption per shot

Reduced Heat Output

Under heavy load, brushless motors generate less heat compared to brushed motors. This reduction in heat output means that even during intense firefights, the grip of your AEG won't become uncomfortably hot to the touch. This not only improves comfort but also contributes to the longevity of the motor and surrounding components.

Increased Longevity

One of the primary advantages of brushless motors is their increased lifespan. The absence of physical brushes means there's no wear and tear from friction, leading to a longer-lasting motor. This durability is particularly beneficial for airsoft players who play aggressively and tend to not save any ammo during intense firefights.

Special Features of Brushless Motors

Many brushless motors also have unique features that set them apart from traditional brushed motors in more ways that extend beyond just the efficiency gains. These in our opinion are even more exciting than the efficiency gains.

Adjustable Speed

Speed-adjustable brushless motors represent a significant advancement in airsoft tuning. Traditionally, changing an AEG's speed required replacing the entire motor, but now a single adjustable motor effectively contains multiple speed options thanks to the built in speed controllers that can adjust the RPM’s without requiring a different physical motor configuration.

This innovation is a game-changer for tuning, allowing players to achieve precise firing rates that were previously extremely hard to achieve, thus offering unprecedented control over their AEG's performance. There are several different mechanisms that allow adjusting of RPMs (and in some cases even torque settings):

• Potentiometer - enables adjustment with a screwdriver to fine-tune RPM, however speed with which the motor spins cannot be determined without a tachometer.

• Switch - allows to toggle between two different speed outputs with a 20% difference which is an easy way to toggle between 2 pre-defined speeds.

• Programmable - enables adjustment using specialized programming cards to set exact RPM and torque settings. However, this method has a drawback – the motor needs to be fully removed from the AEG each time adjustments are made.

• Programmable via Bluetooth - Gate recently introduced firmware update for their Titan II / Aster II ETU's which allows for programming directly through a mobile app when combined with their G5 Smart Brushless Motor, eliminating the need to remove the motor.

One-Way Bearing

Another major improvement that some brushless motors have started incorporating is a one-way bearing, which acts as a built-in anti-reversal mechanism and eliminates the need for an anti-reversal latch (ARL) in the gearbox itself while still allowing pre-cocking (setting that pulls the spring and piston and keeps it compressed just before the gears let it go which improves trigger responsiveness as the motor has to move the gears just a tiny bit to release the piston). 

There are multiple benefits to having the one-way bearing built-in the motor:

• Reduces noise during operation
• Removes a common failure point in the gearbox
• Allows for pre-cocking settings without the risk of reverse rotation

Price differences

While brushless motors have previously been a much more expensive option for airsoft replicas, their prices have been steadily decreasing in recent years, making them more accessible to airsoft players.A few years ago, the cheapest brushless motor would cost at least $250, while today, you can find entry level brushless motors for as low as $90.

That's still quite a bit more expensive than your average brushed motor. That said, as brushless motors gain popularity, economies of scale are driving costs down, and this trend is likely to continue.

Will the brushless motors ever get as cheap as some of the brushed ones? 

Most likely not due to the increased manufacturing costs and needing to have a motor driver built in the motor. But we believe there’s still a bit more room for improvement as brushless motors are just starting to make their way in replicas out of the factory. Only a handful of brands have started doing this but it’s a start and it will surely drive down the cost even more.

Brushless Motor Recommendations

There are now tons of different brands and option on the market but here's our personal favorite suggestions based on our personal testing and experience depending on what you're looking for:

1. Most Feature-Packed: Gate G5 Smart Brushless Motor

A high-end option with adjustable RPM, torque, and a one-way bearing. It's programmable through the TITAN II or ASTER II Electronic Trigger System which ensures effortless adjustment of RPM and torque settings directly from your phone. This is the ultimate package for performance and convenience.

Pros:
+ Adjustable RPM and torque    
+ One-way bearing
+ Programmable via Bluetooth

Cons:
- Not cheap
- Requires TITAN II / ASTER II for programming

Price:  ~ 195€ / $210

Link to buy:  EU & US → TRIDOS.DESIGN 

2. Best Balanced: Solink Advanced Motor 31K

A mid-tier option featuring switchable RPM and a one-way bearing. This will be a perfect drop-in replacement for basically any replica on the market that provides the main benefits of brushless motors with a slight improvement to fire rate without needing any specialized electronics.

PROS

+ 2 different RPM settings
+ One-way bearing
+ Drop-in fit for any replica

CONS

- Limited RPM adjustability
- No torque adjustment

Price:  ~ €120 / $130

Links to buy: EU → Powair6  |  US → Brill Armory

3. Speed adjustment on budget: T238 39K Motor

Great mid-range choice with potentiometer RPM adjustment but no one-way bearing. This T238 Brushless Motor 39K will give you full control of fine tuning RPM’s in a wide range in a more budget friendly package if you’re willing to experiment a bit more. You could even drill a small hole in the grip, to make room for the screwdriver which would allow for adjustments without opening the grip.

PROS

+ Fine RPM adjustment
+ Drop-in fit for any replica
+ Good price

CONS

- No one-way bearing
- Requires additional equipment to determine exact RPM
- No torque adjustment

Price:  ~ €130 / $140

Links to buy: EU → Powair6  |  US → Brill Armory

4. Best Budget: Solink Lite 35K

A budget-friendly option that provides the efficiency gains of brushless technology without any bells or whistles. It doesn’t get much cheaper than this at the moment.

PROS

+ Affordable
+ Improved battery life
+ Drop-in fit for any replica

CONS

- No RPM adjustment
- No torque adjustment
- No one-way bearing

Price: ~ €90 / $90

Links to buy: EU →  Powair6  |  US → Wyshtech Airsoft

Conclusion

While brushless motors may come with a higher initial cost, the benefits in terms of performance, efficiency, and longevity make them an attractive option for players looking to upgrade their AEGs. As prices continue to decrease and technology improves, we can expect to see brushless motors become the standard in high-performance AEG replicas.

If you’re considering upgrading your weapon, make sure to check out G5 Brushless Smart motor listed on our store!