Carbon Brush Market Outlook 2023 to 2033

The global carbon brush market looks set to reach a USD 2,900 million in 2023. From 2023 to 2033, the market is likely to register acceleration owing to a slow 4.5% CAGR.

In 2033, the market’s valuation should surpass the USD 4,503.6 million mark. Between 2023 and 2033, the market also appears capable of generating a USD 1,603.5 million absolute dollar opportunity.

Carbon brushes are widely used in motors, generators and other electrical equipment to transfer electrical current and to prevent arching and electrical sparking. Today, the demand for carbon brushes in the electronic industries is rising due to the increasing use of electric vehicles. According to Future Market Insights (FMI), this factor is set to play a prominent role in the coming decade as the market continues to accelerate.

The benefits of carbon brushes include

  • High melting point (around 3,500 °C)
  • Self-lubrication
  • Soft material
  • Temperature resistance
  • Torque facilitation
  • Wide availability for ease of replacement
  • Cost-effectiveness
  • Commutator-friendly
  • Excellent conduction

Carbon powder/graphite is the popular choice in terms of the material used to produce carbon brushes. Certain manufacturers also use copper for making carbon brushes better conductors in DC applications. However, across AC applications, FMI expects graphite to dominate the overall market for carbon brush.

Particular carbon brushes may also consist of electrolytic copper powder. The use of phenol as a binder is also prevalent. Pitch or other resins can be used as binders as well. Binders ensure that the carbon powder stays in shape when it experiences compaction.

While carbon brushes happen to be the most affordable parts across electric motors, they are often the deciding factor when it comes to motors’ performance and durability. Producing carbon brushes is a challenging process, and as a result, only a handful of manufacturers is participating in the current market scenario.

Apart from the automotive and energy sectors, FMI expects the electrical hand tools segment to boost carbon brush sales in the coming years. This is owing to rising urbanization trends around the world, which is fueling countless construction projects. Across these projects, carbon brush demand is set to soar due to its use in powering electrical hand tools.

Attribute Key Insights
Estimated Carbon Brush Market Value (2023) ~USD 2,900 million
Projected Market Value (2033) ~USD 4,503.6 million
Value-based CAGR (2023 to 2033) ~4.5%
Top Players Share in 2022 ~55 - 60%
Market Statistics Details
Jan to Jun (H1), 2021 (A) 3.3%
Jul to Dec (H2), 2021 (A) 4%
Jan to Jun (H1),2022 Projected (P) 3.8%
Jan to Jun (H1),2022 Outlook (O) 3.7%
Jul to Dec (H2), 2022 Outlook (O) 4.2%
Jul to Dec (H2), 2022 Projected (P) 3.4%
Jan to Jun (H1), 2023 Projected (P) 3.7%
BPS Change : H1,2022 (O) – H1,2022 (P) (-) 10
BPS Change : H1,2022 (O) – H1,2021 (A) (+) 40
BPS Change: H2, 2022 (O) – H2, 2022 (P) (+) 80
BPS Change: H2, 2022 (O) – H2, 2021 (A) (+) 20

The table above primarily provides a pattern of the market’s performance based on changes in the global macro-economic environment. The half-yearly market change in terms of basis points can be a critical indicator for investors to gauge the performance of different markets.

As industrialisation has been a constant driving force, the global automotive industry has witnessed recovery following a lull during the COVID-19 pandemic. There has been an increment in vehicle sales and launches of new models by the OEMs. Increasing semi-conductor availability is also contributing to market acceleration.

Rising prices and increasing interest rates may negatively influence sales. Scarcity of critical raw materials and EV batteries is likely to result in a slowdown of the automotive industry, which might hamper market expansion.

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2018 to 2022 Carbon Brush Market Outlook Compared to Demand from 2023 to 2033

FMI witnessed a sluggish 3.4% for the carbon brush market from 2018 to 2022. During this period, the global automotive and electronic industries dominated carbon brush demand.

Carbon brushes are quite reliable, which means that their lifetime can be extended if they are well maintained with proper care and use. The better the quality of the brushes, the better the performance and efficiency of motors and generators. Sustainability is expected to be the key measure of success for the manufacturing industry, and emphasis on using energy-efficient solutions will promote sustainable manufacturing.

Carbon brushes continue to experience high demand due to its high replacement rate. In recent years, manufacturers have renewed their focus on proper maintenance and on-time replacement of carbon brushes.

Advancements in technology and increased manufacturing of electric motors across various sectors are driving carbon brush sales. These factors should see the market accelerate at a 4.5% CAGR from 2023 to 2033.

What are the Drivers Supporting the Demand for Carbon Brush Market?

High Replacement Rate and Technological Advancements in the Automotive Industry to Drive Carbon Brush Demand

Owing to their high replacement rate, the aftermarket of carbon brushes is the prime sales channel in the market. This is anticipated to significantly drive the growth of the global carbon brush market over the forecast period 2023 to 2033.

Overtime, electronics has emerged as the most pivotal part in the automotive sector. As the technology is advancing, the combination of electronics and automotive systems is expected to open new grounds for market acceleration.

There is increasing interest in passenger cars equipped with smart technologies among consumers. Government schemes and regulations are also boosting the deployment of such technologies in commercial vehicles. As a result, the integration of electronics is expected to significantly drive market expansion between 2023 and 2033.

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Nikhil Kaitwade

Principal Consultant

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Which Factors May Restrict Carbon Brush Sales?

Advantages of Brushless Motors over Brushed Variants to Hamper Carbon Brush Sales

The exclusive use of brushed motors across industries is a thing of the past. Today, industries have the option of adopting brushless motors. Brushless motors offer several advantages over conventional brushed motors, such as

  • Lower heat production
  • Quieter motor operation
  • Longer motor life
  • Better motor efficiency
  • Better power-to-weight ratio

Quite simply, industries keen on improving productivity and efficiency are likely to adopt brushless motors sooner rather than later. If this likelihood becomes a reality, carbon brush sales would plummet. However, brushless motors are more expensive than brushed motors, which means it should take time for this likelihood to turn into a reality.

What Opportunities Does the Market Hold for Carbon Brush Companies?

Increasing Energy-Efficiency Requirements and Escalating Electrification of Rail Infrastructure to Present Opportunities for Carbon Brush Manufacturers

FMI expects multiple opportunities to emerge for carbon brush manufacturers in the coming years. For starters, the demand for energy-efficient motors is on the rise owing to the environmental damage caused by low-efficiency variants. Government regulations are also paving the way for sustainability in the market.

As a result, companies have the opportunity to invest in the development of carbon brushes that can make motors more efficient. Significant demand for carbon brushes should also come from the worldwide railway sector. As electrification of rail infrastructure continues to experience consistent and continuous expansion, carbon brush demand should propel.

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Category-wise Insights

Which Product Type is Likely to Dominate Carbon Brush Sales?

Based on Product Type, Electro Graphite Carbon Brush Sales to Boost the Market

On the basis of product type, FMI expects the electro graphite carbon brush segment to generate substantial sales. Electro graphite carbon brush adoption is thriving in the electronics sector owing to certain advantages over other variants such as

  • Higher commutation resistance
  • Resistance to electrical and mechanical stresses

The worldwide electronics sector should witness stellar acceleration in the years ahead. As a result, electro graphite carbon brush sales are likely to propel. Several key companies in the market have already started to increase their production of electro graphite carbon brushes due to consistently rising demand.

Based on Application, Which Segment is Set to Account for Substantial Carbon Brush Demand?

Surging DC Motor Requirements around the World to Fuel Carbon Brush Demand

On the basis of application, FMI predicts the motor segment to account for significant carbon brush demand between 2023 and 2033. The segment is poised to hold a share of around 33.8% in the global market in the coming years.

The reason for the anticipated expansion and domination of this segment stems from the escalating DC motor demand worldwide. As the demand for DC motors continues to soar, so will the requirements for carbon brushes. Rising AC motor demand is also set to play a pertinent role in shaping the market.

On the Basis of End Use, Which Segment is Poised to Dominate the Market for Carbon Brush?

Industrial Application Segment to Dominate Market for Carbon Brush Owing to Rising Automation Adoption

Based on end use, the industrial application segment is likely to dominate the market for carbon brush from 2023 to 2033. FMI believes rapidly rising automation adoption across industries is the factor that is set to make this segment propel. Defense, construction, and chemical sector are prominent examples of industries that are embracing automation and expanding exponentially.

The segment should also benefit from the intention of industries to maximize productivity across service and manufacturing sectors. This is likely to result in surging electric motor use across industrial applications and boost carbon brush sales in the long run.

Country-wise insights

Country China
Market Share (2023) 24.6%
Market Share (2033) 27.8%
BPS Analysis 320
Country The United States
Market Share (2023) 22.8%
Market Share (2033) 23.4%
BPS Analysis 60
Country Russia
Market Share (2023) 4.5%
Market Share (2033) 4.3%
BPS Analysis -30
Country Germany
Market Share (2023) 3.6%
Market Share (2033) 3.7%
BPS Analysis -30
Country Brazil
Market Share (2023) 3.5%
Market Share (2033) 3.2%
BPS Analysis -30

What is Set to Make China the Leading Market for Carbon Brush?

China’s Positive Attitude towards International Companies and Notable Status as Vehicle Production Hub to Accelerate its Market for Carbon Frush

When it comes to worldwide vehicle production hubs, China is the undisputed frontrunner. In recent years, the country’s vehicle manufacturing output along with annual sales have skyrocketed. FMI anticipates this trend to continue as both local and international vehicle production are set to expand in China.

The country has also opened its doors to companies based in other countries. For instance, in 2019, Toyo Tanso, a Japan-based company specializing in graphite and carbon product manufacturing, established a subsidiary in China’s Sichuan Province. Prior to the establishment of the subsidiary, Toyo Tanso already had a notable presence in the country’s coastal area.

As the country’s automotive industry continues to register impressive acceleration, so would its adoption of carbon brushes. In the East Asia market for carbon brush, China is likely to outperform all other markets. The overall East Asia market is slated to hold a share of 30.4% in the global market over the coming years.

Which Key Factors are Anticipated to Accelerate Carbon Brush Sales in the United States?

The United States’ Substantial Production of Carbon Brushes to Spur Sales from 2023 to 2033

Carbon brush demand is rising across the United States, and FMI does not find it surprising. After all, the United States is among the prominent manufacturers and producers of carbon brushes for conventional motors, drill motors, and variants for electrical and grinding applications.

In the recent past, the United States has seen prominent acquisitions and integrations. For example, in February 2020, Milwaukee-based Helwig Carbon Products, Inc. acquired J. Ream Manufacturing, Inc.’s line of brush holders.

The United States market’s performance would be key for the overall acceleration of the North America industry. In the years ahead, FMI expects the North America market to account for around 26.1% of the global industry. Government initiatives to increase industrial production are also facilitating market acceleration.

Competitive Landscape

The complexities and challenges involved in carbon brush manufacturing have contributed to limited market participation. As a result, there are only a handful of carbon brush manufacturers in the world. In the years to come, they are likely to expand their production facilities through acquisitions. Based on developments from the recent past, they are also likely to focus on launching new products.

For instance

  • In January 2023, Bosch Power Tools launched the GWS 800 Professional angle grinder. The company made the product in Chennai, India, and its exemplary carbon brush was aimed at making maintenance easy.
  • In March 2019, Aupac, a Japan-based carbon brush manufacturer, set up a production facility in Pune, India.

Scope of Report

Attribute Details
Estimated Market Size (2023) USD 2,900 million
Projected Market Size (2033) USD 4,503.6 million
Anticipated Growth Rate (2023 to 2033) 4.5% CAGR
Forecast Period 2023 to 2033
Historical Data Available for 2018 to 2022
Market Analysis USD million for Value
Key Regions Covered North America; Latin America; East Asia; South Asia and Pacific; Western Europe; Eastern Europe; Central Asia; Russia and Belarus; Balkan and Baltic Countries; and Middle East and Africa
Key Segments Covered Product Type, Application, Sales Channel, End Use, and Region
Key Countries Covered The United States, Canada, Mexico, Brazil, Argentina, China, Japan, South Korea, India, ASEAN, Australia, New Zealand, Germany, France, Italy, Spain, BENELUX, NORDICS, the United Kingdom, Poland, Hungary, Romania, Czech Republic, KSA, UAE, Türkiye, Northern Africa, South Africa, and Israel
Key Companies Profiled Morgan Advanced Materials; Mersen SA; Toyo Tanso Co., Ltd.; Robert Bosch GmbH; Schunk GmbH; Pelican Carbon Brush Pvt. Ltd.; Aupac Co., Ltd.; Helwig Carbon Products Inc; Assam Carbon Products Limited.; Naeem Carbon and Industrial Products LLP; Phynyx Industrial Products Pvt. Ltd.; National Carbon Brush Products
Report Coverage Market Forecast, Company Share Analysis, Competition Intelligence, Drivers, Restraints, Opportunities, and Threats Analysis, Market Dynamics and Challenges, and Strategic Growth Initiatives

Carbon Brush Market by Category

By Product Type:

  • General Graphite
  • Metal Graphite
  • Carbon Graphite
  • Electro Graphite
  • Silver Graphite
  • Resin-Bonded Graphite

By Application:

  • Motor
  • Generator & Alternator
  • Current & Signal Transmission
  • Grounding Devices

By Sales Channel:

  • OEM
  • Aftermarket

By End Use:

  • Automotive
  • Electrical Hand Tools
  • Industrial Application
  • Household Appliances
  • Security and Defence
  • Petrochemical
  • Energy
  • Healthcare

By Region:

  • North America
  • Latin America
  • East Asia
  • South Asia and Pacific
  • Western Europe
  • Eastern Europe
  • Central Asia
  • Russia and Belarus
  • Balkan and Baltics Countries
  • Middle East and Africa

Frequently Asked Questions

Why is the Carbon Brush Market Witnessing High Growth?

Increasing demand for electric vehicles is fueling market growth.

What is the Current Market Valuation?

The current market valuation is USD 2,900 million in 2023.

Who are the Key Players in the Carbon Brush Market?

Toyo Tanso Co Ltd and Mersen SA are the key players in the market.

What was the Historical CAGR of the Carbon Brush Market?

The market expanded at a CAGR of 3.4% in the historical period.

Which Region Presents Lucrative Growth Opportunities?

North America is expected to witness lucrative growth opportunities through 2033.

Table of Content
  • 1. Executive Summary
  • 2. Market Overview
  • 3. Key Market Trends
  • 4. Key Success Factors
  • 5. Global Market Demand Analysis 2018 to 2022 and Forecast, 2023 to 2033
  • 6. Global Market - Pricing Analysis
  • 7. Global Market Demand (in Value or Size in USD million) Analysis 2018 to 2022 and Forecast, 2023 to 2033
  • 8. Market Background
  • 9. Global Market Analysis 2018 to 2022 and Forecast 2023 to 2033, By Product Type
    • 9.1. General Graphite
    • 9.2. Metal Graphite
    • 9.3. Carbon Graphite
    • 9.4. Electro Graphite
    • 9.5. Silver Graphite
    • 9.6. Resin-Bonded Graphite
    • 9.7. Others (Impregnated)
  • 10. Global Market Analysis 2018 to 2022 and Forecast 2023 to 2033, By Application
    • 10.1. Motor
    • 10.2. Generator and Alternators
    • 10.3. Current and Signal Transmission
    • 10.4. Grounding Devices
    • 10.5. Others
  • 11. Global Market Analysis 2018 to 2022 and Forecast 2023 to 2033, By Sales Channel
    • 11.1. OEM
    • 11.2. Aftermarket
  • 12. Global Market Analysis 2018 to 2022 and Forecast 2023 to 2033, By End Use
    • 12.1. Automotive
    • 12.2. Electrical Hand Tools
    • 12.3. Industrial Application
    • 12.4. Household Appliances
    • 12.5. Security and Defence
    • 12.6. Petrochemical
    • 12.7. Energy
    • 12.8. Healthcare
  • 13. Global Market Analysis 2018 to 2022 and Forecast 2023 to 2033, by Region
    • 13.1. North America
    • 13.2. Latin America
    • 13.3. Europe
    • 13.4. East Asia
    • 13.5. South Asia and the Pacific
    • 13.6. Middle East and Africa (MEA)
  • 14. North America Market Analysis 2018 to 2022 and Forecast 2023 to 2033
  • 15. Latin America Market Analysis 2018 to 2022 and Forecast 2023 to 2033
  • 16. Europe Market Analysis 2018 to 2022 and Forecast 2023 to 2033
  • 17. South Asia and Pacific Market Analysis 2018 to 2022 and Forecast 2023 to 2033
  • 18. East Asia Market Analysis 2018 to 2022 and Forecast 2023 to 2033
  • 19. Middle East and Africa Market Analysis 2018 to 2022 and Forecast 2023 to 2033
  • 20. Country Wise Market Analysis
  • 21. Market Structure Analysis
  • 22. Competition Analysis
    • 22.1. Morgan Advanced Materials
    • 22.2. Mersen SA
    • 22.3. Toyo Tanso Co., Ltd
    • 22.4. Robert Bosch GmbH
    • 22.5. Schunk GmbH
    • 22.6. Pelican Pvt. Ltd.
    • 22.7. Aupac Co., Ltd.
    • 22.8. Helwig Carbon Products Inc.
    • 22.9. Assam Carbon Products Limited
    • 22.10. Naeem Carbon and Industrial Products LLP
    • 22.11. Phynyx Industrial Products Pvt. Ltd.
    • 22.12. National Products
  • 23. Assumptions and Acronyms Used
  • 24. Research Methodology
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