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Custom Brushes For Industrial and High Tech Applications

Our Services

Custom Engineering Service

Tod Thin Brush custom design services, application analysis, complete prototype and product development capabilities, enable us to engage customers on a unique level. Whether it's helping to define the problem, provide turnkey/black-box assemblies, or video link access to solid modeling examples, ours is a truly comprehensive approach.

This breath of experience allows us to first design, then manufacture and delivers a differentiated product to best meet your specific needs.

What is more, multiple CAD licenses means that our designers can move within virtually any software without translation; and when translation is required, the process is entirely seamless to our customers. This design acumen truly sets us apart. Taken together with our manufacturing capabilities and material knowledge, you'll find that TOD Thin Brushes has the manufacturing design expertise guaranteed to deliver.

Custom Brushes from Jefferson, Ohio

Design and development of strip brushes, as well as other types, are our core areas of expertise at TOD Thin Brushes. We extend our design and development services for a variety of components, ranging from micro-miniature brushes to large, intricate brushes and other high-tech applications.

Custom Brush Types

Prototype runs, as well as high-volume production runs, of more than 250,000 pieces can be manufactured. Various types of material in the backing and filaments, along with custom modifications on some of the components we produce, are done through precision brush manufacturing.

Antistatic Brush

As defined by the EIA and the ESD Association, refers to the property of a material that inhibits triboelectric charging. A material that inhibits the generation of static charges (generally less than 200Vlts) from triboelectric generation is classified as antistatic. These materials would be arranged in the triboelectric series near cotton, an electrically neutral material. Materials ordered in either side of cotton generate some static charge, but in very small amounts. Note: An antistatic material can be conductive, dissipative, or even insulative. Only antistatic or dissipative antistatic materials should be used in ESD safe areas. Only contact with a conductive material can damage a charged device.

Dissipative Brush

Allow charges to move more slowly across their volume. Charge placed in one spot on a dissipative object will flow around the object so that all parts of the object share the same charge. If a charged dissipative material is grounded, charges will recombine at a slower rate until the object has no charge. Dissipative materials have a resistance to current flow that is greater than conductors, but less than insulators.

Conductive Brush

Allow charges to move freely across their surface or through their volume. Charge placed in one spot on a conductive object will flow around the object so that all parts of the object are equally charged. If a charged conductor is grounded charges will recombine (move ground) until the object has no charge. Conductive materials have a low resistance to current flow. This is because the dissipation of static charges from grounded conductive material tends to be complete and rapid. Ungrounded conductors can generate and hold static charges.

Insulative Brush

Does not allow charges to move across their surfaces or through their volume. Charge placed in one spot on an insulative object will stay in that location. If a charged insulator is grounded, charges will not move to ground. Grounding is not an effective method of neutralizing insulators. Insulators can have both negatively and positively charged areas on the same object. Because insulators do not allow charge movement, they can accumulate massive amounts of charge. Static fields on insulators are not necessarily permanent; they will eventually be neutralized by gradual recombination with free ions.

ESD EOS Brushes

Static charge is generated between materials through friction, pressure or separation of two materials, one of which is usually non-conductive. This process is called the Triboelectric Effect (tribo means rubbing). The actual level of charge is measured in coulombs. Commonly, however, the electrostatic potential on an object is expressed as a voltage.

In addition to the material composition, applied forces and separation rate, relative humidity is an important factor in the generation of static charges.

When humidity is low, higher static charges are generated more easily. Static becomes more noticeable in the winter months, in dry climates, and in air-conditioned environments. Increasing humidity to 60% limits static build-up as surface moisture on materials makes a good conductor. Unfortunately, 60% relative humidity is extremely uncomfortable can cause equipment problems and introduce contaminants.

There are two sources of static damage to electronic devices: EOS (Electrostatic Overstress) and ESD (Electro Static Discharge).

EOS occurs when an electronic device is exposed to a strong static electric field generated by a static charge. Internet electronic components stressed beyond their designed tolerances may fail immediately or have reduced service lives.

ESD occurs when two objects of different electrostatic potentials are brought close enough together to allow a charge transfer. ESD is the sudden discharge of this electrostatic potential from one body to another. If the discharge current exceeds designed tolerances, damage may cause immediate failure or result in reduced service life.

Brush Seals

The use of metal channel strip brushes as sealing devices have been proven as successful barriers in many applications. The millions of filaments in our brush strips seals conform to irregularities between uneven surfaces while allowing a full range of motion for moving parts while far outperforming vinyl or rubber strips.

Our brushes provide a virtually frictionless seal that locks out light, hot or cold air, sound, vapors, sprays, dust and other contaminants. In fact, metal channel strip brushes can prevent an impressive 98.5% of air infiltration, which provides for a quick return on investment in energy savings.

Custom Brush Filaments

Today's high tech and industrial brush engineering require the flexibility for a custom manufacturer to work with varied filaments.

We have materials with multiple diameters, pitch requirements, density specifications, and performance standards for heat, light, static control, conductivity and insulative properties.

Natural Hair Fibers

  • Goat Hair
    A very fine hair with limited elasticity. It has a natural kink that cannot be straightened. Used for short, soft bristle brushes like cosmetic brushes. Comes in natural black and white, dyed blue, brown, gold, green, gray and purple.

  • Hog Bristle
    Relatively scarce and expensive. This material has characteristics that set it apart as the best natural filling material for a wide variety of bristle brushes. Each strand of bristle has a natural taper from the butt or flesh end to the tip, giving it resilience not found in other hairs. In addition, the tip end of each bristle is naturally split into two or more branches called the flag. Hog bristle has a slightly stiff to very stiff texture and is brown or black in color excellent for ESD applications. It has excellent durability and water resistance.

  • Horse Hair
    Horsehair is a medium to high cost material. Tail hair is stiffer than mane hair. Its soft to slightly stiff texture gives a scratch-free dry cleaning and has very good durability. Not resistant to acids or alkalis. Used for buffing, cleaning, dusting, and finishing in a variety of bristle brush styles: floor sweeps, shoe shine brushes, tin handle acid brushes, counter dusters, and window brushes, excellent for ESD applications. Heat distortion temperature is 370deg F.

  • Ox Hair
    In proportion to its diameter, ox hair is perhaps the stiffest of all soft hairs. Ox hair is particularly sought after in artist or dental brushes for fine lettering, striping and marking brushes.

  • Red Sable
    The hair of the red sable is the most valuable of all soft hairs. It is very fine, has strong sharp points and great elasticity and carries color well. Red sable hair makes the finest artists' brushes, being particularly suited for use with Japan colors, oil colors and heavy-bodied sign-writing materials, and is best for fine lettering. Pure red sable hair has a perpetual taper, creating the finest point possible on a bristle brush.

  • Skunk or Fitch
    This hair is rarely used alone. Combined with Chinese hog bristle, it makes excellent sign writer's brushes. Grey skunk hair from eastern and western Europe has been found to be ideal for bristle brushes used in the manufacture of shade cloth.

  • Squirrel
    This hair is divided into blue squirrel and Canadian squirrel. A very fine hair used for applying thin lacquers, Japan colors, light -bodied varnishes, and for general artwork, lettering and stripping as well as cosmetic brushes.

Natural Organic Filaments

Does not allow charges to move across their surfaces or through their volume. Charge placed in one spot on an insulative object will stay in that location. If a charged insulator is grounded, charges will not move to ground. Grounding is not an effective method of neutralizing insulators. Insulators can have both negatively and positively charged areas on the same object. Because insulators do not allow charge movement, they can accumulate massive amounts of charge. Static fields on insulators are not necessarily permanent; they will eventually be neutralized by gradual recombination with free ions.

Nylon Based Filaments

  • Nylon Abrasive
    A long-wearing abrasive nylon filament impregnated with silicone carbide particles. We stock several filament diameters and silicone carbide particle sizes.

  • Nylon type 6
    Provides a good durable nylon with good recovery, temperature stability and abrasion resistance at a low cost.

  • Nylon Type 6.6
    Top quality, medium-priced with higher stiffness, recovery and abrasion resistance than type 6. It has the highest heat distortion temperature of the three nylons at 300 deg F.

  • Nylon type 6.12
    Superior type nylon used in applications calling for low water absorption. It has excellent recovery, and abrasion resistance. This is the highest-grade nylon. Because they resist rot and mildew and discourage bacterial growth, nylon 6.12 bristle are widely used in food service bristle brushes.

  • Nylon-Conductive
    A type 6.6 nylon with an electrically conductive coating suffused onto the surface for anti-static bristle brush applications. Available in three standard diameters .010, .016, and .020. Average electrical resistance is 7.8 x 10-3 ohm/cm.

  • Polyester
    A polymer that replaces horsehair. It features of toughness and high temperature resistance resembles those of Nylon, but Polyester is noted for its ability to recover without whip or slapping action (will not mat). Polyester has excellent resistance to all acids, alkalis, alcohols, gasoline, benzene and most cleaning solvents. It is a medium- priced filament that resists mildew, bacteria and fungus growth.

  • Peek
    A durable thermoplastic that offers good chemical resistance and is ideal for high heat and corrosive environments. Peek provides excellent flexural and tensile strength up to 480 deg F and is a great alternative to Teflon.

  • Polyethylene
    A soft durable material suitable for applications where abrasion is to be avoided. These flexible bristles are very efficient for thorough washing and polishing of delicate fruits and vegetables. Polyethylene is ideal for soft wiping instead of brushing action.

  • Polypropylene
    A versatile low cost filament used for a wide variety of applications. Polypropylene will not absorb moisture or odors and sheds dirt easily. It has excellent wet stiffness, abrasive tip cleaning action, non-brittle, and is inert to most solvents, oil, acids, and chemicals. It is in fact one of the most chemically resistant synthetic filament materials.

  • Polystyrene
    This material has replaced natural bristles for use where chemical resistance is needed. Its stiff aggressive properties make it ideal for utility brushes, coffee urn brushes, deck scrub brushes, floor and garage brushes. Polystyrene bristles wear longer, perform better and yet carry a comparable price tag to natural bristles.

  • Tynex A
    A long-wearing abrasive nylon filament impregnated with silicone carbide particles. We stock several filament diameters and silicone carbide particle sizes.

Acrylic Filaments

  • PVC
    An economical material with a reasonable flex life, low friction resistance and no loss of stiffness in water.

  • Teflon
    A polymer that is inert to most chemicals, resistant to strong mineral and oxidizing acids, along with alcohols, ketones, ethers, amines, esters, chlorinated compounds and common cleaning solvents. Teflon has excellent property resilience up to 500 deg F.

  • Thunderon (R)
    An acrylic fiber that has been chemically bonded with a layer of copper sulfide. This outer layer becomes a part of the host fiber itself, which precludes the 'flaking' problem experienced by other conductive fibers. The fiber diameter is as fine as .004 cm (.0015") and its conductive layer is a super thin 300-1,000A(angstroms). IT has electrical specific resistance of 10 (to the first degree) - 10 (second degree ohm/cm.

Metal Filaments

  • Aluminum
    Soft and non-corrosive. Bends easily and takes a set. Recommended for special applications only.

  • Brass. 360 Aloy
    The softest metal fiber available in either straight or crimped. Used for light to medium cleaning and luster finishing.

  • Carbon Steel
    Available both tempered and un-tempered, in a variety of sizes, straight or crimped. This is a widely used metal fill material. It has excellent cutting ability and fatigue resistance for long brush life at a low cost. It is used for general-purpose cleaning, rust removal, deburring, edge blending and roughing for adhesion.

  • Nickel Silver
    This alloy nominally contains 65% copper and 18% nickel. The alloy's electrical conductivity is about 6% that of copper. Very resistant to most chemicals this alloy is used in staple wires as well as fill material.

  • Philosphor Bronze
    C51000, phosphor bronze B, is non-sparking and about 1/5 as conductive as copper. Stronger than brass (F73 Rockwell) and lasts longer. Resists corrosion and fatigue due to flexing.

  • Stainless Steel
    Type 302 stainless for wet and nor rust applications in a variety of sizes, straight or crimped, which is highly corrosive and heat resistant. Unlike carbon steel, stainless steel does not leave after-rust deposits when used on stainless steel, aluminum, and other high-strength alloys. However, once used ion carbon steel it cannot be used on stainless steel or rusting can occur. Used in corrosive environments for general purpose cleaning, rust removal, deburring, edge blending, and roughing for adhesion.

  • Beryllium Copper
    Also known as copper beryllium, BeCU or beryllium bronze, is a metal alloy of copper and 0.5 to 3% beryllium, and sometimes with other alloying elements. Beryllium Copper combines high strength with non-magnetic and non-sparking qualities. It has excellent metalworking forming and machining qualities. It has many specialized applications in tools for hazardous environments, musical instruments, precision measurement devices, bullets, and aerospace. Beryllium-containing alloys create an inhalation hazard during manufacturing due to their toxic properties.

Carbon Fiber

A very fine (.0003 diameter) fiber of 94% pure carbon. Fiber has a tensile strength of 525 Ksi, a tensile modulus of 33 Msi, and an electrical resistivity of .00055 Ohm/in.

Custom Brush Modification

We have manufactured 1000s of brushes over the past 51 years with varied options including, but not limited to holes, notches, attachments, grounding mechanisms, wire attachments, bends, arcs, angles, and pressure sensitive applicators. Our custom manufacturing caters to the needs of the engineering requirements demanded for the client's performance standards.

Notches, arcs, and angles are included in our line of profile brushes, which offer several modifications to the filaments in the brushes. Allowing for a greater flexibility in the design of the clients products.

TOD Thin Brushes offers custom filament pitch on strip and thin strip brushes, which includes a special 1,2,3,4 and 5mm pitch on all materials including stainless steel filament thin strip aluminum backed pressure sensitive applicator.

The Production Process

We employ several production methods, and our miniaturization methods are fast, reliable and multi-functional, producing lightweight parts that deliver great performance. Dies and tools are engineered in-house to maintain tight tolerances of up to 0.005 inches. Our experts produce high-quality tooling for all our applications.

Quality control and quality enhancement are valued by our manufacturers for all custom brush types. Contact us in Jefferson, Ohio, for details on our methods.