Abstract-This study is concerned with the minimization of cogging torque component, by taking into account magnet thickness and pole embrace value for small power battery-fed brushless DC motors (BLDCMs) with high efficiency and high reliability. Distinct values of magnet thickness and embrace are defined in the specified range for the design and comparatively mentioned in the paper. Depending upon the magnet thickness and pole embrace, the obtained new magnet shapes are modelled on a comparative basis using both analytical approach and finite element analysis (FEA). The BLDCM with low cogging torque and optimal magnet shape is designed by the help of 3D FEA by considering the magnetic flux density distributions. In addition, the magnet shape's effect on the motor parameters such as motor efficiency, output power, and air gap flux density is discussed throughout the paper. The analytical results are verified by the transient FEA.