There are many ways to produce industrial brushes, and all of the methods described below have been used.
Staple Set Brush
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Staple set construction is commonly used for rotary (disk) brushes and cylindrical brushes. Typical uses include the floor care, vegetable and fruit industries,and some industrial brushes. This construction allows for excellent filament flexibility in the brush, but tuft retention can be a problem.
Metal Strip Brush
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Metal strip construction is typically found in cylindrical brushes, either wound around a brush core or inserted into extruded aluminum hubs in a straight line lengthwise along the shaft.Typical uses are finishing and cleaning flat metal sheets such as printed circuit boards or aluminum and steel coil. Long trim length brushes are also made in this style. This is a very durable construction.
Epoxy Set Brush
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Epoxy set construction is found in both rotary (disk) and cylindrical brushes. This method is growing as new techniques are developed. The end uses for this construction include deburring, floor care, and flat metal sheet finishing. This construction also allows for excellent filament flexibility. Aggressive brushes with high filament density are possible.
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Twisted-in-wire construction is almost always used in a power brush application for metal finishing of holes in objects. This construction holds the densely packed filaments very tightly so brushes can be used in very aggressive applications. Filament length can vary from very short to very long.
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Wound construction is typically used in cylindrical brushes wrapped on a core. The filaments can be wound with rope or wire. The most common application for this brush is for cleaning printed circuit boards. This style is not used in very aggressive applications because the filaments are not held as tightly on the brush core as other styles.