Views: 0 Author: Site Editor Publish Time: 2026-01-15 Origin: Site
If you've worked with small BLDC motors long enough, there's a good chance you've felt it.
On paper, everything looks fine. The motor meets the torque requirement, fits the voltage range, and comes from a well-known supplier. But once the product enters real-world testing—or worse, pilot production—subtle issues start piling up.
By 2025, many engineers quietly began asking the same question:
“Should we still be using a small BLDC motor here?”
For a growing number of precision applications, the answer turned out to be no. And in 2026, the shift toward coreless motors has become easier to explain—and harder to ignore.
To be fair, small BLDC motors are not “bad.” They're robust, efficient, and widely available. That's exactly why so many projects start with them.
But problems tend to show up in applications that demand:
Fast dynamic response
Smooth low-speed motion
Compact mechanical integration
Low noise and vibration
These are precisely the areas where BLDC motors begin to show their limits—especially at small sizes.
As products shrink, inertia becomes a bigger deal.
In small BLDC motors:
The rotor mass stays relatively high
Laminations add inertia
Acceleration and deceleration feel sluggish
In precision systems—such as medical devices, optical modules, or small robotic actuators—that inertia translates into:
Overshoot
Slower response
More aggressive control tuning
Coreless motors eliminate the iron core, dramatically reducing rotor inertia. The difference often becomes obvious the moment the system is powered on.
Many precision applications don’t run at high speed. They operate near zero—or oscillate around it.
Here's where engineers often get stuck with small BLDC motors:
Cogging torque becomes noticeable
Control loops grow increasingly complex
Motion no longer “feels” precise
Coreless motors, by design, offer:
Nearly cog-free rotation
Smooth torque output
Predictable behavior at low speed
For engineers focused on motion quality rather than raw power, this shift alone can justify the change.
At this point in the decision process, most engineers do something very practical:
They stop comparing theories—and start comparing actual motor options.
They want to see:
Diameter ranges
Length options
Typical torque and speed windows
Customization potential
Not all coreless motors are the same, and subtle design differences matter.
Brushed Coreless Motors (Ø X–X mm)
Ironless Slotless DC Motors
High-Speed Coreless Motors for Compact Systems
Customized Coreless Motor Assemblies
Positioning note:
Place your Modar Motor coreless motor catalog or series list here, immediately after this section.
At this reading stage, users are ready to scan real products, not marketing claims.
Noise issues are often underappreciated—until users start noticing.
In practice:
Small BLDC motors can introduce audible electrical noise
Mechanical vibration leaks into enclosures
Noise mitigation becomes a mechanical problem
By contrast, coreless motors tend to be:
Quieter
Easier to isolate
More forgiving in compact housings
During 2025, many engineers reported noise improvements simply by switching motor topology—without redesigning the entire system.
What looks simple on a block diagram rarely stays simple.
With small BLDC motors, engineers often end up managing:
Extra space for housings
Alignment constraints
Additional mechanical tolerances
Coreless motors, especially in precision assemblies, integrate more naturally into tight designs. The motor becomes part of the structure—not an object bolted onto it.
This distinction matters more as products aim for:
Cleaner mechanical layouts
Reduced part counts
Smaller footprints
BLDC motors often require:
More complex controllers
Careful commutation tuning
Additional filtering
Coreless motors, particularly brushed versions, can simplify control significantly—an advantage for teams focused on speed-to-market or cost-sensitive designs.
Even where control sophistication is required, the predictable electrical behavior of coreless motors often shortens development cycles.
Some of the strongest arguments for switching emerge after prototyping.
As projects move into production, engineers encounter:
Unit-to-unit variation
Unexpected vibration behavior
Assembly sensitivity
Here, the supplier's manufacturing discipline matters.
Manufacturers with experience in consistent winding, balancing, and medium-scale production—such as Modar Motor—often support smoother transitions from prototype to volume, particularly for coreless motor programs.
Several 2025 trends pushed engineers toward coreless motors:
Increased focus on energy efficiency
Demand for quieter devices
More compact system architectures
Shorter development timelines
By 2026, this shift feels less like experimentation and more like a strategic upgrade.
Coreless motors aren't the answer for everything.
Small BLDC motors still make sense when:
Power levels are higher
Continuous torque dominates
Standardization matters more than motion finesse
The real mistake is assuming one motor type fits all use cases.
Switching motor technology often exposes gaps—not in the design, but in supplier collaboration.
Engineers value manufacturers who:
Speak in system terms
Offer honest trade-offs
Support controlled customization
This is why engineering-driven suppliers like Modar Motor naturally appear in these transitions—not as aggressive promoters, but as quiet problem-solvers.
Engineers rarely change core components without reason.
When they move from small BLDC motors to coreless motors, it's usually after firsthand experience—after trying to make something work and realizing the limitation isn’t the algorithm or the mechanics.
In 2026, the growing shift toward coreless motors reflects a deeper truth:
precision products demand precision behavior—and sometimes that starts inside the motor itself.
