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Brush Construction - Brushes 101


Our brushes are built in a large variety of constructions with the highest degree of accuracy and precision. Choose between brush types, various style backings, a range of brush sizes and an array of filament patterns. Brushes can be reshaped, resized and reimagined for nearly any job.

SHAPES AND STYLES

Wheel brushes

Wheel brushes are ideal for industrial finishing and deburring applications.

Disc brushes

Disc brushes are used for deburring, finishing and polishing.

Twisted-in-wire brushes

Twisted-in-wire brushes are commonly used for internal deburring and cleaning.

Metal back strip brushes

Metal back strip brushes are manufactured for internal and external surface finishing.

Ferrule end brushes

Ferrule end brushes are used for deburring and finishing.

These brushes are constructed either using stapled set filament tufts or using coil construction by winding a straight metal channel strip brush around a core cylinder center.

The core provides the necessary diameter and brush length. While the channel brush style, filament type and wrap density provide the necessary filament concentration, abrasiveness and chemical resistance.

Channel brush and stapled set patterns can also be customized to address specific needs -- including helical, herringbone and other patterns -based on movement and scrub requirements. Coils can be wound left or right facing, can have loose wound or tight wound patterns or can vary by pitch -all impacting movement and abrasive affects.

Power brushes are comprised of two main components, the mounting hardware and filament. Mounting hardware secures the brush head to the power device. The brush filament, combined with the working action of the powered machinery provides performance brush action ideal in surface conditioning applications.

SHAPES AND STYLES

Tanis provides standard power brushes in three general configurations:

COPPER CENTER WHEEL:

  • Wheel shape with filaments attached on the external surface of a copper tube
  • Filaments secured by a punch press and a washer
  • Available with a fixed or adaptable arbor hole
Copper Center Wheel

END:

  • Brush filaments are permanently end-mounted on 1/4" drive shanks
  • Conflare, radial, circular flared, solid, miniature and square trim shapes available
  • Available with wire, natural or abrasive fill material
  • Ideal for cleaning confined or hard-to-reach areas
End Brush

CUP:

  • Circular cup brush end
  • Permanently mounted on steel stem
  • For mounting in portable and flexible tools
Cup Brush

METAL BACK STRIP ROTARY BRUSHES

Rotary Brushes

Coiled metal back strip brushes are manufactured by winding a straight metal back strip brush around a core construction. The metal back strip brush consists of densely compressed filament laid into an unformed metal strip which is formed vertically into a "U" shape by a binding wire.

The strips are coiled close wound under pressure to produce a dense brush face or open wound for less density. A larger winding pitch provides a less dense brush and conforms better to the surface being brushed. Once the coil is finished, Tanis can then assemble it to a core, a shaft or supply it unassembled for mounting on installed equipment.

STANDARD CORE SYSTEMS

  • Solid stainless steel or steel shaft with journal ends machined to your requirements. Recommended shaft sizes between 1/2" to 2". Due to weight of the final assembly, we recommend shaft sizes not to exceed 2" diameter.
  • Stainless steel or steel tubing is used for the core. Journal ends for drive and bearing surfaces are press fit and shrunk inside the tube. The journal ends are either stainless steel or steel.
  • Stainless steel or steel tube with end collars to accept customers’ shaft size. Tube diameter can be made to any size. Collars are made with set screws and/or single or double keyways. Design is recommended for slower speed applications.

STAPLED SET ROTARY BRUSHES

Stapled set rotary and wheel brushes are manufactured by inserting individual tufts of filament into a drilled hole in a block of plastic and securing with a staple. The staple is made of steel or nickel-silver which is predicated by the environment and the conditions the brush will be performing under.

CORE CONSTRUCTION

Stapled set rotary brushes are made with an extruded or machined plastic core pressed onto a shaft or core. The core can either be press fit onto a shaft, an internal tube with collars to accept an installed shaft, or a tube construction with journal ends. Plastics including polyvinylchloride (PVC), polypropylene, high-density polyethylene (HDPE), ultra-high molecular weight (UHMW), ABS or delrin are used as core materials.

Tanis also features a bonded core technology casting urethane material onto a shaft as another core construction for stapled rotary brushes. The urethane is cast directly to the metal shaft.

Stapled set wheel brushes are made with a round, plastic block including an arbor hole. Bearings can be press fit into the arbor hole, if required.

THE STANDARD CORE SYSTEMS ARE:

  1. Solid stainless steel or steel shaft with journal ends machined to your requirements. Recommended shaft sizes between 1/2" to 2". Due to weight of the final assembly, we recommend shaft sizes not to exceed 2" diameter.
  2. Stainless steel or steel tubing is used for the core. Journal ends for drive and bearing surfaces are press fit and shrunk inside the tube. The journal ends are either stainless steel or steel.
  3. Stainless steel or steel tube with end collars to accept customers’ shaft size. Tube diameter can be made to any size. Collars are made with set screws and/or single or double keyways. Design is recommended for slower speed applications.
  4. Stainless steel or steel tubing with flange mounted journal ends for drive and bearing surfaces. Tube diameters usually range from 4" to 12". This design used for long shaft ends for better support. The ends are either shrunk in place or connected by screws for permanent fit.
Standard Core Systems

Stapled set brushes are available in six general shapes:

FLAT OR LAG:

  • Most common brush shape and style
  • Square or rectangular shaped backing
  • Option to be machined with mounting holes for easy installation
  • Easiest and most cost effective to design and manufacture
Flat or Lag

DISC OR FACE:

  • Round, flat block material
  • Filament secured only to one side of the brush at a right angle
  • Option to be machined with a drive hole or mounting holes for easy attachment
Disc or Face

GOBLET OR DOMED:

  • Molded plastic block with domed or mushroom shaped head
  • Block molded with or without handles
Goblet or Domed

BELT:

  • Flexible brush belts available in different configurations
  • V-belt, flat belt and toothed belt styles are available
Belt

WHEEL:

  • Round plastic block with arbor hole
  • Bearing can be press fit into arbor hole, if required
Wheel

ROTARY:

  • Extruded or machined plastic block pressed onto a shaft or core
  • Urethane based material cast onto shaft or core
Rotary

METAL BACK STRIP BRUSHES

Metal Back Strip Brush 1

Metal back strip brushes are manufactured using densely compressed filaments laid down uniformly onto an unformed metal strip. A binding wire is inserted over the filament causing it to form vertically as the metal backing closes and forms into a "U" shape over the binding wire and the filament. All strip brushes are initially manufactured straight and then can be formed into many different shapes such as a coil, cup or ring style. Metal back strip brushes are the most economical brush manufactured due to the simple form of construction.

Metal Back Strip Brush 2

STAPLED SET BRUSHES

Tanis manufactures stapled set strip brushes by firmly securing filament material into an extruded PVC backing with a staple. Brush products using either flexible or rigid PVC backing are available. The flexible PVC backing allows this strip brush construction to contour to different shapes and around corners, addressing problems the metal back brushes cannot.

Stapled Set Brushes 1
Stapled Set Brushes 2

Twisted brushes are manufactured by twisting layers of bristle between stem wires. There are three different stem constructions, each offering various strength and density characteristics:

  • Single-Stem, Single-Spiral consists of a single layer of filament twisted between two stem wires.
Single-Stem, Single-Spiral
  • Double-Stem, Single-Spiral brushes have one layer of filament twisted between four stem wires with two stem wires on each side for additional strength and higher density fill.
Double-Stem, Single-Spiral
  • Double-Stem, Double-Spiral brushes have one layer of filament twisted between four stem wires with two stem wires on each side for additional strength and higher density fill.
Double-Stem, Double-Spiral

SHAPES AND STYLES

There are three classifications of twisted brushes, determined by the brush diameter:

  • Miniature brushes have a diameter of .250" or smaller and are generally made with a finer stem wire and are available in metric sizes from 1.0mm to 6.5mm brush diameters and standard inch sizes from .020" to .250" diameters.
Miniature Brush
  • Hand brushes have a diameter of .125" or larger and are made with larger stem wire for manual cleaning. Some hand brushes can be power driven by cutting off the loop for more aggressive applications.
Hand Brush
  • Power brushes have a diameter of .250" or larger, are generally made more rigid and use a bigger stem wire to be power driven in a drill, drill press or CNC machining center.
Power Brush

SHAPES AND STYLES

Our hand brush product offering includes the following brush shapes and styles:

HAND SCRATCH BRUSHES:

  • Plastic or wood handle – either bent, curved, straight or upright
  • Rows of filament on one brush end
  • Several available fill materials including wire, synthetic nylon and natural
  • Used most often as a welders tool but also for general cleaning purposes
Hand Scratch Brush

GENERAL PURPOSE BRUSHES:

  • Delrin, plastic, wood or metal block handle – either curved, bent or flat
  • Filament is hand drawn into the handle
  • Several sizes
  • Used for general industrial cleaning
General Purpose Brush

HAND STEEL WIRE SCRATCH BRUSHES:

  • Densely filled with one to four rows of trim
  • Wood shoe or curved handle
  • Available with tempered steel, stainless steel, brass and phosphorous bronze filaments
Hand Steel Wire Scratch Brush

PLATERS’ BRUSHES:

  • Hardwood block handles – either shoe, curved or flat
  • Available with various wire, nylon or bristle filaments
  • Used for general industrial cleaning and plating applications
Platers' Brush

ANILOX OR HALFTONE BRUSHES:

  • Water resistant, laminated solid hardwood block
  • Clear laquered finish
  • Densely filled on one entire side of the block synthetic, natural or wire filament
  • May have hand grooves
  • For cleaning anilox rollers
Anilox or Halftone Brush

An artist brush is comprised of three main parts, the handle, bristles and a ferrule. The bristles carry and apply liquid to a surface and the ferrule is a metal band that attaches the bristle to the handle. It is important to consider how the brush feels in your hand, to make sure that you are comfortable holding the brush, as this may be the most important determination of brush characteristics.

The handle of the brush is often made from wood that can be provided unfinished or finished with an applied paint or lacquer. The length of the handle can vary from extremely short to very long and ideal length depends on the brush use. If the brush is going to be used for detailed work, a short handle is recommended, but if the brush is used for larger coverage areas, a long handle may be more effective.

There are many different types of bristles, each having different characteristics that will affect the durability of the brush and how the liquid is applied. If you should have a question about which bristle type is right for your application, a Tanis technical salesperson will be available to assist you. What is important about the bristles is that they are firmly secured by the ferrule, as to not shed during use. A high-quality ferrule should not come loose or rust throughout the life of the brush.

SHAPES AND STYLES

Our artist brush product offering includes the three brush styles which are classified by the shape of the bristles:

Flat brushes have bristles inserted into the ferrule so that they lay flat and wide, but not very thick. The bristle tips are cut to produce a blunt edge. Lacquering brushes are a type of flat brushes.

Flat Brush

Marking brushes have a traditional round brush shape that may come to a finer point, depending on the size and bristle type.

Marking Brush

Stroke brushes are generally a denser and wider round brush for applying liquid in heavier strokes.

Stroke Brush

Standard paint brushes are manufactured by inserting durable natural or synthetic fill into a plastic, wire or wood handle. The filaments are then secured using a high-quality, rust-resistant metal ferrule. The round or flat metal ferrule is tightly bound around the handle of the brush, balancing the bristles to prevent the brush tip from losing its shape. The bristles are set in epoxy and the handles are solvent resistant to extend brush life.

SHAPES AND STYLES

CHIP BRUSHES:

  • Used for cleaning small parts and applying paint
  • Polyester, bristle or stainless steel wire
  • Plastic or wire handle
  • For use with resins, glues, acetone
Chip Brush 1 Chip Brush 2

SASH BRUSHES:

  • Can be flat or angled
  • Made with pure bristle for smooth finish
  • Typically for enameling and trim work
  • Comfortable plastic handle
Sash Brush 1 Sash Brush 2

Standard parts cleaning brushes are manufactured by inserting durable natural or synthetic fill into a metal or wood handle and securing either through a plating process or using a ferrule. The bristles are set in epoxy and the handles are solvent resistant to extend the life of the brush. Most utility brushes, including most of our parts cleaning brushes, use a metal ferrule in their construction. The high-quality metal ferrule should remain tightly secured and resistant to rust.

Standard Parts Cleaning Brush

The Tin Handle Brush is an example of a brush that is produced using a plating process. The filament is inserted into a tin tube and then an enormous amount of pressure is applied to securely clamp the tin onto each of the fibers. The amount of weight that is used in this process reduces the brushes desire to shed fibers during use, especially when applying a viscose substance.

Tin Handle Brush