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 Brush Construction Methods

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HAND SET BRUSHES- Unusual brushes for which the best method of manufacturing has been manual assembly.  No machine method has been perfected.  A skilled craftsman must put the proper amount of brush material together with a brush ferrule.  Then epoxy or rubber secures the brush in place so that a handle can be attached, and the final assembly process can take place.  Years of technique and experience are used by the brushmaker.  Higher quality artist and sash style brushes are generally produced with this method. 

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PLUGGED AND KNOTTED-Made by hand similar to using hand set methods.  Brushes for which no machine method has been perfected.  3 knot roofing, 4 knot roofing styles, glue brushes, and sash brushes. 

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STAPLE SET BRUSHES-Utilizing the modern method of brushmaking.  A double length of brush material is automatically tufted and secured in place by the use of a metallic staple. Many brushes are staple set such as floor sweeps, counter dusters, vehicle wash and scrub brushes.

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TWISTED IN WIRE-Brush material is placed between one or two wires and firmly twisted to form a brush.  The brushes are made on automatic machinery and are usually low cost and very durable brushes.  They are bottle and tube cleaning styles.

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WIRE WOUND-A groove is cut into the handle and the brush material is wound around the grooves by use of a continuous wire.  The brushes are unusual shapes and designs.  Used for cleaning brushes for the food industry.  Also, for general maintenance in bottle, glass and bowl cleaning brushes.

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METAL GRIP-Brush material is laid flat across a strip of metal and wire is laid across the center.  The metal crimps around the brush material and wire forming a strip brush.  Strips can be used straight or formed into a variety of brushes such as: Push Brooms, Wound Brushes, Coiled Brushes, Conveyor Brushes, and even Counter Duster brushes.

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HAND WIRE DRAWN-Each tuft is drawn into its proper position and formed into a tuft by the craftsman using a continuous length  of wire.  Still an effective method for superior tuft retention and for unusual design brushes.

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