The operation of conveyors, automated guided vehicles, packaging lines, and valve actuators in industrial facilities is being enabled by DC motor systems that provide simple voltage-based speed control and high starting torque. Analysis presented by Market Research Future reveals that as industrial automation increases, demand for DC motor systems continues to grow.

Report Key Statistics

Market Research Future's analysis indicates that the Brushed DC Motor Market was valued at USD 19.40 billion in 2025, with projections to reach USD 32.67 billion by 2035 at a CAGR of 5.35%. Industrial is the largest application, with a 29.6% share in 2025.

The Less Than 75 kV band holds 91.4% of market revenue in 2025. The Between 75 kV - 375 kV band represents heavy industrial drive systems, valued at USD 1.26 billion.

Industry Trends: Material Handling and Retrofit Applications

The most significant trend in DC motor systems for industrial automation is the growth in material handling applications including conveyors and automated guided vehicles.

Retrofit projects favor brushed gearmotors for their simple control and high starting torque.

Medical and personal-care device demand is growing, with coreless brushed units selling at a 3–5x per-unit price premium over iron-core equivalents.

Challenges: Brush Wear and Efficiency Requirements

Brush wear affects service life in continuous-duty applications.

Tightening motor efficiency regulation shapes procurement specifications. The US DOE's updated electric motor standards carry compliance from June 2027.

Competition from brushless motors affects high-end applications.

Future Outlook: Condition Monitoring and Data-Driven Service

The future of DC motor systems for industrial automation lies in condition monitoring that predicts remaining brush life from electrical signatures.

Fleet operators of automated guided vehicles, vending machines, and medical pumps will pay for predictive maintenance alerts.

This opens recurring service revenue and data subscription models for motor suppliers.

Expert Discussion: Application Requirements

Industry observations from Market Research Future highlight the importance of understanding duty cycles when selecting DC motor systems.

Brushed units offer simple voltage-based speed control and high starting torque, which makes them standard in auxiliary motion axes and retrofit projects.

The International Federation of Robotics recorded 541,302 new industrial robot installations in 2023, extending automation growth well beyond robot arms.

Conclusion

The Brushed DC Motor Market industrial segment continues to evolve as automation requirements increase. While challenges related to brush wear, efficiency requirements, and competition persist, ongoing innovation ensures continued improvement. The evolution toward condition monitoring and data-driven service will define the next generation of industrial DC motor systems.

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