About the Brushes
Brush Manufacture – The Process
Step 1 – processing of raw materials
Filaments; we use both natural bristles and synthetic filaments in a variety of shapes according to final requirement. These are straightened and sorted to length and then mixed by machine to create different blends for use with different types of paints. According to the final use of the brush, we will blend stiff or soft mixes with absorbency to suit. Most of our filaments are flagged (cut at the top) in order to give a smooth finish to any painting task.
Handles; plastic handles are injection moulded or rubberised to create a comfortable grip for painters working over long periods. Our wooden handles are all of long lasting hardwood which are first sanded smooth for a comfortable grip and then stabilised by kiln drying to ensure no swelling in use.
Ferrules; high grade stainless steel is mostly used. These are cut to the required length, embossed with the relevant size marking and then folded, stamped and punched in a unique process to create a tightly locked ferrule that fits snugly to the handle.
Step 2 – Brush Assembly
Brush head making; each brush ferrule is filled with a measured weight of filling and then compacted using a wedge. This wedge holds the filling in place before gluing and creates a space for paint to load up. The measured weight ensures that the glue, once poured into the back of the brush head, sits perfectly and locks the filling into place securely.
Once the wedge is in place, the filling is then tamped down to give an even length at the “root” end and the head is then pulled up to the required visible length out from the ferrule and then combed straight so that the filaments achieve an even flow of paint to the tips.
Gluing and Assembly; using the correct dosage and ratio of epoxy resin and hardener is of paramount importance and even though most of today’s paints are water based, our resins are solvent resistant to ensure good performance in all kinds of paint. Our Ultrabond process ensures constant and consistent resin flow and allows for complete control of resin penetration to give a full “lock” around our filaments and ferrules.
All Spirit and Swift brush heads are then moulded to shape and will have a “memory” and will point perfectly in use.
Once the resin has set, the brushes are ready to assemble on to handles. They are nailed and, in the case of Spirit brushes, anchored using metal inserts that sit between the ferrule and the handle, providing a “double lock” to fix the head onto the handle. Our handles are made of hardwood birch and beech that has been stabilised in kilns that we have on site or injection moulded plastic with a full rubberisation process available for our Comfi range.
Our brushes are then cleaned of any loose filaments through our “flirting” machines that take out any strands of hair that might not have set in the resin and also flag the filaments ( i.e. splitting of filament tips) to give a smooth painting finish when used.