Brush Molding

Brush bodies - from household cleaning tools to industrial brushes - combine bristle tufts, metal components, and plastic handles. Vertical injection molding holds bristle inserts in position during clamping, producing durable, assembly-ready brush products.

DA Series vertical machines can be reviewed for brush molding. Slide table configuration is commonly considered when bristle or insert placement needs accessible loading outside the clamp area.

Application Overview

Brush molding with vertical injection machines

The process

Bristle tufts, metal ferrules, or handle cores are placed into the lower mold. The vertical clamp closes from above, holding the inserts in their cavities. Plastic is injected around the inserts, forming the brush body, and after cooling the finished brush is ejected.

This eliminates secondary bristle-setting and handle assembly - the brush body, bristle anchor, and grip are produced as a single integrated component in one molding cycle.

Why vertical clamping for brush production

Bristle tufts are flexible and unpredictable - they don't stay put like rigid metal inserts. Vertical clamping and accessible mold loading work together:

Slide table moves the lower mold out for operator placement of bristle tufts
Gravity holds tufts in their cavities while the clamp closes from above
Metal ferrules, threaded inserts, and handle cores remain in position
Overmolding soft-grip handles in the same cycle for complete brush assembly

Common Challenges

Production challenges in brush molding

Bristle handling, insert placement, and product structure all affect the right machine choice - each brush type presents different production requirements.

Product structure variation

Brush designs vary widely - toothbrushes, paint brushes, industrial brooms, cleaning tools - each with different bristle types, body geometries, and insert requirements. Machine configuration must match the specific product structure and bristle anchoring method.

Slide table workflow for bristle placement

Bristle tufts must be placed accurately and quickly. Slide tables move the lower mold out for ergonomic loading - the operator places tufts, confirms position, and the table returns to the clamp area. Double slide tables can further improve throughput.

Customization for non-standard requirements

Special brush geometries, multi-material handles, or automated bristle feeding may need custom machine configurations. The engineering team can discuss custom platforms after reviewing product design, bristle type, and production targets.

Configuration Review

Recommended machine configuration for brush molding

Starting points - final selection depends on brush design, bristle type, mold layout, and production volume.

Machine series

DA Series

Standard vertical clamping + vertical injection. Covers brush body, handle, and bristle-insert molding. Slide table or fixed platen. 15T-800T.

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Table configuration

Slide table

Lower mold slides out for accessible bristle placement. Single or double slide - commonly preferred for brush production.

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Machine size must be confirmed from project data - Review projected mold area, cavity count, material, brush body size, and insert layout before selecting tonnage.

Materials

Typical materials for brush molding

Brush body material selection balances durability, chemical resistance, grip comfort, and cost - each material type brings different processing characteristics.

PP (Polypropylene)

Most common brush body material. Good chemical resistance, cost-effective. Used for household cleaning brushes, brooms, and general-purpose brush handles.

PA66 (Nylon)

For industrial and heavy-duty brushes. Higher strength and heat resistance than PP. Glass-fiber grades for structural brush components.

TPE / TPU

Soft-touch overmold for brush grips and ergonomic handles. Bonds to PP and PA substrates. Common for toothbrushes and consumer cleaning tools.

ABS

For consumer brush products requiring good surface finish and color options. Common for toothbrushes, cosmetic brushes, and household cleaning tools.

POM (Acetal)

For precision brush components - sliding mechanisms, retractable brush systems. Low friction, good dimensional stability.

PET (recycled)

Recycled PET grades for sustainable brush products. Good mechanical properties, processable on standard vertical machines. Growing demand in consumer brush markets.

Products

Typical brush molded products

From household to industrial - these product categories represent common brush molding applications on vertical injection machines.

Household cleaning brushes

Scrub brushes, dish brushes, toilet brushes with molded-in bristle tufts and ergonomic handles.

Personal care brushes

Toothbrushes, hairbrushes, cosmetic applicators with precision-molded bodies and bristle anchoring.

Industrial & specialty brushes

Heavy-duty brooms, street sweeper brushes, industrial cleaning tools with reinforced bodies.

Soft-grip handle brushes

Brushes with TPE/TPU overmolded grips - combining rigid body and soft-touch handle in one cycle.

DA Series - Standard Vertical Injection Vertical clamping + vertical injection, 15T-800T. Covers brush body molding applications. Slide Table Machines Single and double slide table for accessible bristle and insert loading. Insert Molding Related process - molding around bristle tufts as inserts. Overmolding Related process - overmolding soft grips onto brush handles.

FAQ

Brush molding - frequently asked questions

Why use a vertical injection molding machine for brush production?

Brush bodies often combine bristle tufts, metal ferrules, or handle inserts with a plastic body. Vertical clamping holds these components in position by gravity during mold closing - critical when bristle tufts could shift in a horizontal machine. Slide tables provide accessible loading for bristle placement.

Which table configuration is recommended for brush molding?

Slide tables are commonly preferred - the lower mold slides out for accessible bristle tuft placement and insert loading. Single or double slide depending on production volume and part complexity. Fixed platen may suit simpler brush geometries.

How should machine size be reviewed for brush molding?

Tonnage should be reviewed from brush body size, projected area, cavity count, material, bristle or insert layout, and mold design. A brush category alone is not enough to select the machine size.

Which machine series is commonly reviewed?

DA Series (standard vertical clamping + injection, 15T-800T) is commonly considered for brush molding. Slide table configuration provides accessible loading for bristle placement. Selection depends on product structure, insert type, and production workflow.

What materials are used for brush bodies?

PP for general-purpose brush bodies. PA66 for structural brush components. TPE/TPU for soft-grip brush handles (overmolded). POM for precision brush components. Material selection depends on brush type, durability requirements, and chemical resistance needs.

Can a machine be customized for specific brush designs?

For non-standard brush geometries, multiple insert types, or automation integration, the engineering team can discuss a custom machine platform after reviewing brush design, bristle type, mold layout, and production targets.

How do I discuss machine configuration for brush molding?

Send your brush design, bristle and insert specifications, material, mold dimensions, and production volume. An applications engineer can review the project data and discuss machine series, table configuration, and machine-size direction.

Tell us about your brush molding application

Discuss machine configuration for brush production

Send your brush design, bristle specifications, material, mold dimensions, and target production volume. The engineering team can review the project data and discuss a suitable configuration path.

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