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This paper manufactures a prototype of DC motor made of soft magnetic composite (SMC) core, and compares the motor efficiency with that of a motor made of the laminated core. Next, this paper develops a method for DC motor simulation, where the 2-D FEM is directly coupled with brush and commutator circuit. Finally, in order to improve the motor efficiency, eight geometry design parameters are optimized by using the experimental design method. The highest efficiency of the optimized motor is improved from 53.7% to 68.9%, that is, the improvement of 15.2%.