Acoustic noises generated during motor operation in mechanical system are from electromagnetic, mechanical, aerodynamic and electrical sources. For identification of mechanical noise origins, misalignment, unbalance, fan shape, resonance, and vibration modes have been extensively considered to describe noise behavior. An experiment-based approach as well as a mathematical approach needs to be adopted for a realistic study into noise and vibration of the motor, because motor noise characteristics differ from type to type due to various noise sources. This paper analyzes noise characteristics of a brushless DC motor for air-conditioner fan, and proves that the test motor noise originates from acoustic modes of airspace in the motor. The motor noise sensitivity analysis by design of experiments reveals that the noise characteristics are closely related to switching frequency and frame thickness.