The authors address the modeling problem associated with brushless DC motors (BLDCMs) with nonuniform air gaps that operate in a range where magnetic saturation may exist. The mathematical model includes the effects of reluctance variations as well as magnetic saturation to guarantee proper modeling of the system. An experimental procedure is developed and implemented in a laboratory environment to identify the electromagnetic characteristics of a BLDCM in the presence of magnetic saturation. It is demonstrated that the modeling problem associated with the class of BLDCMs can be formulated in terms of mathematically modeling a set of multidimensional surfaces corresponding to the electromagnetic torque function and the flux linkages associated with the motor phase windings. The accuracy of the mathematical model constructed by the developed method is checked against experimental measurements