Why is the hollow cup brushless motor so expensive?

Why is the hollow cup brushless motor so expensive?

Why are coreless brushless motors more expensive than brushed motors, in-rotor brushless motors, and out-rotor brushless motors? The primary reason lies in the triple premium effect stemming from their material costs, performance advantages, and application scenarios.

The highlight of the material is the hollow cup rotor, which uses micrometer-level self-supporting copper wire for winding (ironless copper winding), with copper purity requirements exceeding 99.9%. The material usage increases by 40% compared to traditional windings. The magnets employed are high-performance neodymium-iron-boron magnets, accounting for over 30% of the total cost. In contrast, brushed motors only require ordinary magnetic steel, resulting in lower costs. Due to the extremely high rotational speed of the hollow cup, high-performance components such as ceramic bearings are necessary, with costs 3-5 times higher than those of conventional bearings.

High Performance of Coreless Brushless Motors:
Brushless motor: Lifespan extended by 5 times (up to 5000 hours), energy conversion efficiency >90% (brushed motors only 60%)

Brushless interior and exterior rotors: 1.5 times higher power density (30% higher torque at the same volume), response time <10ms (exterior rotor >30ms)

Domestic scarcity: 70% of global production capacity is monopolized overseas (e.g., Germany's Faulhaber), with a localization rate of less than 10%, driving up prices due to scarcity.

The Premium for High-End Customization of Coreless Brushless Motors:
It is commonly used in high-end products such as medical equipment, robots, high-speed trains, automobiles, and smart homes, and its price is significantly higher than that of conventional motors.

When you need a motor for R&D, the coreless brushless motor can meet your requirements. However, it's essential to understand the cost of coreless brushless motors. Customers unfamiliar with these types of motors may find them more expensive than the final product they develop. ‌‌