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Carbon Brush Market

The market for Carbon Brush was estimated at $936 million in 2024; it is anticipated to increase to $1.28 billion by 2030, with projections indicating growth to around $1.65 billion by 2035.

Report ID:DS1401148
Author:Swarup Sahu - Senior Consultant
Published Date:
Datatree
Industrial Tools & Machinery
Production Tools & Equipment
Carbon Brush
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Report Summary
Market Data
Methodology
Table of Contents

Global Carbon Brush Market Outlook

Revenue, 2024

$936M

Forecast, 2034

$1.57B

CAGR, 2025 - 2034

5.3%

The Carbon Brush industry revenue is expected to be around $985.6 million in 2025 and expected to showcase growth with 5.3% CAGR between 2025 and 2034. This sustained ascent in the Carbon Brush market clearly underlines the prominent role these components continue to play across various industries. Driving factors attributable to this rising significance include technological advancements, growing electrification of transport, increased dependency on power generation, and the necessity for regular maintenance of electrical and motor-based systems. Being crucial in electrical apparatus and enabling effective electric current exchange, the importance of carbon brushes is profoundly embedded in the modern industrial sector.

Primarily made up of powdered or granulated carbon and housed in a brush holder, a Carbon Brush is fundamentally an electrical contact. It serves diverse applications ranging from power tools and household appliances to industrial motors and generators. Recent industry trends highlighting the adoption of green energy solutions and the upsurge in renewable power generation have given impetus to the demand. Also, continuing needs in sectors like automotive and electrical also contribute to the popularity of Carbon Brush.

Carbon Brush market outlook with forecast trends, drivers, opportunities, supply chain, and competition 2024-2034
Carbon Brush Market Outlook

Market Key Insights

  • The Carbon Brush market is projected to grow from $936.0 million in 2024 to $1.57 billion in 2034. This represents a CAGR of 5.3%, reflecting rising demand across Motors, Generators, and Alternators.

  • Morgan Advanced Materials, Mersen, Schunk Group are among the leading players in this market, shaping its competitive landscape.

  • U.S. and China are the top markets within the Carbon Brush market and are expected to observe the growth CAGR of 3.4% to 5.1% between 2024 and 2030.

  • Emerging markets including Brazil, Indonesia and South Africa are expected to observe highest growth with CAGR ranging between 6.1% to 7.3%.

  • Transition like Electrification of Transportation has greater influence in U.S. and China market's value chain; and is expected to add $35 million of additional value to Carbon Brush industry revenue by 2030.

  • The Carbon Brush market is set to add $633 million between 2024 and 2034, with manufacturer targeting Generators & Alternators Application projected to gain a larger market share.

  • With

    acceleration of power generation and industrialization, and

    Advancements in Automobile Industry, Carbon Brush market to expand 68% between 2024 and 2034.

carbon brush market size with pie charts of major and emerging country share, CAGR, trends for 2025 and 2032
Carbon Brush - Country Share Analysis

Opportunities in the Carbon Brush

With the increasing global shift towards the adoption of electric vehicles, there is also a burgeoning market for carbon brushes. These devices are integral components of the electric motor systems used in electric vehicles. The global electric vehicle market is experiencing remarkable growth, providing ample opportunities for the expansion of carbon brush applications.

Growth Opportunities in North America and Europe

The North American region, with an emphasis on the United States, stands as a prominent player in the carbon brush market. This is primarily driven by extensive use of carbon brushes in various industrial applications such as electric motors, generators, alternators, battery chargers, and other static and rotary machines. The presence of well-established industries augment the demand, making it a diverse and robust market. Factors like the rising need for electrical equipment in the automation sector and escalating construction activities amplify the demand for carbon brushes. However, fierce competition prevails in this region, with an array of carbon brush manufacturers and suppliers jostling for market share.
Europe, particularly Western Europe, is another key region for the carbon brush market. Advanced technological infrastructure there necessitates the use of carbon brushes in numerous applications such as automotive, power generation, and industrial equipment. Emerging trends, like electrically powered vehicles and renewable energy installations, also contribute significantly to the demand for high-performance carbon brushes in the region. Simultaneously, the dynamic competitive landscape in Europe is characterized by the presence of both global and regional carbon brush manufacturers, with strategic collaborations and R&D investments being their key competitive strategies. To remain competitive, manufacturers in this region are focusing on improving the overall reliability, lifespan, and performance of carbon brushes.

Market Dynamics and Supply Chain

01

Driver: Rising Demand for Industrial Motors and Electric Vehicles Driving Carbon Brush Market Growth

The growing adoption of industrial motors and the rapid expansion of electric vehicles are also key drivers of the carbon brush market. In industrial motors used across manufacturing, mining, and automation, carbon brushes provide reliable electrical contact, reducing wear and maintaining consistent performance under heavy loads and continuous operation. Concurrently, the global EV revolution increases the need for high-performance DC motors in traction and auxiliary systems, where graphite and metal-graphite brushes ensure durability, low friction, and thermal stability. Technological advancements in brush materials, such as self-lubricating composites and optimized graphite grades, improve lifespan and efficiency. Together, these trends expand carbon brush adoption in industrial automation and automotive electrification, creating sustained market growth.
A significant driver is also the advancement of carbon brush materials for generators and alternators, particularly in power generation and automotive sectors. Innovations in electrographite, metal-graphite, and high-performance composite brushes improve current carrying capacity, reduce arcing, and enhance thermal stability under continuous high-speed operation. These developments enable generators and alternators to operate efficiently in harsh industrial and automotive environments, reduce maintenance frequency, and extend equipment lifespan. Manufacturers leveraging advanced materials and coating techniques gain a competitive advantage, driving higher adoption of carbon brushes in critical power transfer applications worldwide.
02

Restraint: Accelerating Adoption of Brushless Motor Technologies Reducing Carbon Brush Demand

One of the most significant restraints facing the carbon brush market is the widespread shift toward brushless motor technologies, especially in electric vehicles, precision equipment, and consumer electronics. Brushless DC (BLDC) motors eliminate the need for physical brushes by using electronic commutation, leading to higher efficiency, lower maintenance, quieter operation, and longer lifespan. As adoption of BLDC systems grows in automotive traction systems, HVAC applications, and robotics, reliance on traditional carbon brushes declines. For example, studies show nearly 37–39 % of new motor installations now favor brushless designs, which directly reduces carbon brush demand in high‑growth segments and limits overall market expansion.
03

Opportunity: Technological Innovations in Carbon Brush Manufacturing and Strategic Collaborations in the Carbon brush sector

Advanced manufacturing techniques are leading to the production of more efficient and durable carbon brushes, stimulating market growth. Developments in material science and engineering technologies enhance the performance characteristics of carbon brushes, driving their demand in various industrial applications. Tech-savvy manufacturers stand to gain from these technological advancements by offering improved carbon brushes aligning with evolving market needs.
Establishing strategic partnerships and collaborations with leading players in the automotive, industrial equipment, and electrical machinery sectors can provide significant growth opportunities for carbon brush manufacturers. Such collaborations could facilitate co-development of superior quality, customized carbon brushes catering to the specific needs of these sectors, paving the way for market expansion and revenue growth.
04

Challenge: Raw Material Price Volatility and Supply Chain Disruptions Impacting Profitability

Another key market challenge for carbon brushes is raw material price volatility and supply chain instability, particularly for graphite, copper, and silver used in brush manufacturing. Fluctuating commodity prices such as recent graphite increases of up to 30–45 % raise production costs and compress profit margins for manufacturers. These cost pressures often translate into higher end‑product prices, which can dampen demand in cost‑sensitive markets like consumer appliances and light industrial motors. Additionally, supply chain disruptions and longer lead times for specialty materials complicate production planning and delivery schedules, affecting revenue and competitive positioning for brush suppliers.

Supply Chain Landscape

1

Raw Material

Graphite Mining CorporationsCarbon Compound Producers
2

Intermediate Processing

Industrial Carbon ManufacturersPower Carbon Limited
3

Production

Morgan Advanced MaterialsSchunk Group
4

End User

AutomotiveHome AppliancesPower Generation Industries
Carbon Brush - Supply Chain

Use Cases of Carbon Brush in Motors & Generators

Motors : In motors, carbon brushes are critical components that maintain electrical contact between stationary circuits and rotating commutators or slip rings, especially in DC and AC motors used across automotive, industrial machinery, and consumer devices. Typically carbon graphite or metal-graphite brushes are used for their excellent electrical conductivity, self‑lubricating properties, and heat resistance, which enhance motor performance and longevity under varying loads. Leading suppliers such as Mersen, Schunk Group, and Helwig Carbon Products provide advanced brush materials designed to reduce wear, minimize arcing, and extend service life in high‑speed motors operating in industrial automation, traction systems, and electric vehicles. Their strong R&D and global distribution support reliable performance and cost‑effective maintenance for OEMs and end‑users alike.
Generators : For generators, including those in power plants, backup power systems, and renewable energy installations, carbon brushes like soft graphite and metal‑graphite grades are essential for transferring current to the rotor’s slip rings. These brushes ensure stable electrical output, reduce maintenance needs, and support continuous operation under high mechanical stress and variable environmental conditions. Market leaders such as Mersen and Schunk design generator‑specific brush grades with high transient current capacity, low friction, and mechanical stability tailored to applications from hydroelectric and thermal plants to wind turbine alternators. Their expertise in material selection and customization enhances generator reliability and lifespan, reinforcing their competitive positions in the global power generation equipment market.
Alternators : In alternators, including automotive and industrial alternators, carbon brushes maintain current flow between the stationary and rotating parts to ensure efficient power generation and voltage regulation. Typically electrographite and metal‑graphite brushes are employed for their ability to handle high current densities and resist wear in high‑speed rotational environments. Companies like Mersen, Morgan Advanced Materials, and Toyo Tanso offer specialized alternator brush solutions featuring optimized conductive materials and robust designs to withstand thermal fluctuations and long duty cycles. These suppliers leverage extensive experience and innovation to deliver high‑performance alternatives that enhance alternator reliability, reduce downtime, and meet diverse application requirements across automotive and industrial power systems.

Recent Developments

Recent developments in the carbon brush market reflect expansion in renewable energy, industrial automation, and electric motor applications. Demand for high-performance metal-graphite and electrographite brushes is rising as wind turbine generators and advanced motors require reliable electrical contact and reduced maintenance. A key market trend is the shift toward brushless technologies and smart manufacturing, where sensors and material innovations improve brush life and performance analytics. Despite this, carbon brushes remain critical in heavy-duty generators and legacy systems, balancing traditional demand with emerging technological improvements in materials and predictive maintenance.

December 2024 : Leading player in the Carbon Brush industry, Bosch Power Tools, unveiled its newest line of carbon brushes that significantly improve lifespan and power transmission efficiency, offering unprecedented durability
September 2024 : Helwig Carbon Products, another prominent carbon brush manufacturer, revolutionized the market by introducing its patent-pending Carbon Dust Mitigation Technology that ensures a cleaner and more efficient working environment
April 2024 : Morgan Advanced Materials highlighted the integration of a state-of-the-art AI system into their production line, raising the bar for Carbon Brush manufacturing through ultra-precise automation.

Impact of Industry Transitions on the Carbon Brush Market

As a core segment of the Production Tools & Equipment industry, the Carbon Brush market develops in line with broader industry shifts. Over recent years, transitions such as Electrification of Transportation and Expansion of Renewable Energy have redefined priorities across the Production Tools & Equipment sector, influencing how the Carbon Brush market evolves in terms of demand, applications and competitive dynamics. These transitions highlight the structural changes shaping long-term growth opportunities.
01

Electrification of Transportation

As the world edges closer to environmental sustainability, the electrification of transportation has become a paramount concern for many industries. This transition has led to a surge in the demand for carbon brushes, which are vital components in electric motors and generators used in electric vehicles. Carbon brushes ensure that these motors run smoothly and efficiently, impacting the performance of the hybrid and fully electric vehicles. The automotive sector, in particular, has witnessed a significant rise in electric vehicle production, consequently boosting the demand for carbon brushes. This transition has not only impacted the carbon brush industry but also augmented growth in associated industries such as automotive manufacturing and electric component suppliers.
02

Expansion of Renewable Energy

The global shift toward renewable energy is creating significant opportunities for the carbon brush market. As wind, hydro, and solar power installations expand, carbon brushes are increasingly used in wind turbine generators and hydroelectric alternators to maintain stable electrical contact and ensure uninterrupted energy transmission. For instance, modern wind turbines rely on durable metal-graphite and electrographite brushes to handle high currents and rotational speeds, minimizing maintenance downtime. Additionally, the growth of renewable energy infrastructure drives demand for electric generators across power plants and microgrid systems, indirectly boosting carbon brush consumption. This transition strengthens the market’s role in supporting reliable, sustainable power generation and reinforces adoption across energy sectors worldwide.