High starting torque, simple drive integration, and cost-effective volume manufacturing built to your exact load profile and winding specification.
Drawing-controlled specifications
Prototype to volume scaling
ISO-certified quality system
40 years of OEM program experience
Brushed DC motors remain an essential motion choice for continuous and duty-cycle OEM applications. Rather than relying on complex external inverter drives, permanent magnet brushed DC (PMDC) and coreless DC configurations utilize simple DC power or straightforward Pulse-Width Modulation (PWM) speed control. This simplifies control topology, reduces total bill-of-materials cost, and minimizes integration risk.
Since 1985, Telco Intercontinental Corp. has co-engineered custom brushed DC motors alongside global OEM design teams. We analyze your supply voltage, peak and continuous torque requirements, duty cycle, ambient thermal boundaries, and envelope constraints to deliver engineered motion solutions backed by documented drawings and change control.
The parameters below represent typical platform capabilities. Every Telco motor is customized around your specific duty cycle, mounting envelope, shaft configuration, and thermal limits.
| Parameter | Standard Range | Custom Engineering Capability |
|---|---|---|
| Operating Voltage | 12V – 180V DC | Custom voltage matching (6V to 240V DC) for battery or line power |
| Power Output | 10W to 5kW continuous | Intermittent peak power scaling up to 10kW |
| Rated Speed | 500 RPM – 8,000 RPM | Winding modification for optimized speed-torque curves |
| Efficiency Rating | 75% – 88% | Optimized magnet grade (Ferrite, NdFeB) and segment skewing |
| Frame Sizes | NEMA 42 to NEMA 256 (Ø 28mm – Ø 120mm+) | Custom die-cast endbells, extruded housings, and mounting flanges |
| Enclosure Ratings | Open Frame, TENV (Totally Enclosed Non-Ventilated), TEFC | IP54 to IP67 sealing with custom shaft oil seals |
* Data represents baseline platform ranges. Technical specifications are frozen upon design review and first-article drawing approval.
We resolve early-stage design trade-offs by evaluating electromagnetic, acoustic, and thermal criteria upfront before tooling commitments are made.
Brush wear is dictated by current density and mechanical friction. Telco matches graphite, electro-graphite, or precious metal brushes with diamond-turned commutators to maximize operational life.
For noise-sensitive laboratory, medical, and commercial environments, we integrate internal varistors, EMI suppression capacitors, dynamic armature balancing, and continuous skewing.
Eliminate costly adapter plates. We provide integrated worm, spur, or planetary gearheads, custom shaft flats, keyways, splines, leadscrews, and specific connector harnesses.
From initial engineering review to recurring production delivery, Telco maintains documented revision management and quality gates.
Define operating duty cycle, continuous and stall torque, target voltage, and space envelope.
Electromagnetic and thermal modeling to optimize winding density, flux distribution, and stack height.
Build functional prototypes with full empirical lab testing for in-system validation.
Conduct life-cycle, thermal rise, vibration, and EMI testing prior to first-article inspection (FAI) approval.
Volume assembly with rigid change control, process audits, and inventory buffer management.
Brushed DC motors feature simple two-wire drive electronics and basic PWM speed control, eliminating the cost and technical complexity of inverter drives. They deliver maximum torque at stall and are optimal for intermittent duty, cost-sensitive assemblies, or high-volume applications where brush life exceeds equipment service requirements.
Telco customizes armature windings to target specific continuous torque, operating speeds (RPM), and supply voltages ranging from 12V to 180V DC. We also optimize thermal class insulation, brush material formulations, and commutator geometries for target duty cycles.
We match brush compositions (precious metal, graphite, or electro-graphite) with diamond-turned commutators, low-noise sleeve or ball bearings, and integrated EMI/RFI suppression capacitors to maximize brush lifespan while maintaining minimal acoustic ripple.
For modified standard platforms, prototype samples can typically be delivered within 4 to 6 weeks. Ground-up clean-sheet designs requiring custom lamination stacks or special housing tooling usually run 8 to 12 weeks through first-article inspection reports.
Speak with a Telco application engineer to review your torque targets, mechanical constraints, and annual volume requirements.