Case Studies

Boosting Power Tool Performance with Naxatra Labs’ Advanced BLDC Motor Solution

Overview

In the competitive world of power tools, performance, durability, and efficiency are critical differentiators. While lithium-ion batteries have revolutionized cordless tools, traditional brushed DC motors remain a bottleneck—hindering the full potential of modern equipment.
This case study explores how Naxatra Labs’ high-efficiency Brushless DC (BLDC) motor solution enabled a significant performance leap in industrial-grade power tools. By replacing conventional brushed motors with a smarter, more durable alternative, manufacturers are seeing measurable gains in runtime, reliability, and long-term cost savings.

The Challenge

Most industrial power tools today still rely on brushed DC motors. Though cost-effective, they come with serious drawbacks:

Inefficiency & Energy Loss: Brushed motors operate through physical contact between brushes and a commutator, causing friction. This leads to energy loss as heat, with peak efficiencies typically limited to ~75–80%.
Shorter Runtime: Energy waste reduces battery life, limiting cordless tool performance in high-demand environments.
Wear & Maintenance: Constant friction causes brush and commutator wear, increasing maintenance frequency and downtime.
Noise & Vibration: Mechanical contact creates excessive operational noise and vibrations—problematic in tools used for 8+ hours a day.
Safety Concerns: Electrical arcing at the contact points makes brushed motors unsuitable for hazardous environments. unless heavily certified.

Our Solution

Naxatra Labs introduced a custom-engineered Brushless DC (BLDC) motor specifically designed for power tool applications. The goal: eliminate the mechanical limitations of brushed motors while unlocking higher efficiency and smarter control.

Key Features of Naxatra’s BLDC Motor

Electronic Commutation

Replaces brushes with sensor-driven electronic switching, enabling frictionless operation, minimal wear, and zero sparking.

Optimized Stator-Rotor Design

Uses neodymium permanent magnets on the rotor and copper windings in the stator, enabling higher torque and power density in a smaller form factor.

Superior Thermal Management

Heat is dissipated more effectively from the stator, keeping operating temperatures lower and extending component lifespan.

Integrated Control & Intelligence

Enables precision features such as variable speed control, torque limiting, soft start/stop profiles, and safety interlocks—features impossible with mechanical commutation.

Performance Comparison

Energy and Cost Impact

For reference a 150W tool, BLDC being about 30% more efficient, if the tool operates about 3,000 hrs. in a year, the energy saved is about 135 kWh. That’s about 1,350 INR (at 10 rupee/ unit) saved every year not to mention the savings due to reduced down-time and maintenance costs. Thereby also reducing the overall Total Cost of Ownership.
Reduced energy consumption aligns with potential future regulations and appeals to environmentally conscious customers and corporations with sustainability mandates.

IMPACT

150W tool used
3,000 hours/year

The way ahead

As the industry shifts toward brushless systems, offering BLDC-powered tools is no longer a premium add-on it’s becoming a baseline expectation. The result of this study unequivocally demonstrates that Naxatra Labs’ motor technology provides a transformative upgrade over traditional brushed DC motors for power tools applications. The documented improvements in efficiency, power, battery runtime, durability, thermal management, and noise reduction collectively address the core limitations of brushed technology and directly translate into significant business advantages for power tool manufacturers.
If you’re a power tool manufacturer looking to future-proof your products and stay ahead of the curve, Naxatra Labs can help. Our team specializes in custom BLDC motor solutions designed for high-performance industrial applications.

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