Step 1: Weighing: The process starts with weighing the bristles.
Step 2: Combing: Once weighed, the bristles are combed to untangle and smooth them out.
Step 3: Alignment Profiling: For this purpose the hair bundle is placed tip-first into the “forming block” and carefully “tapped” until the desired profile is accomplished.
Step 4: Tie Thread: To secure the bristles, they are tightly bound using thread, which ensures they stay together and gives the brush its initial shape.
Step 5: Pulling: Excess bristles that aren’t neatly secured are pulled out.
Step 6: Wire Cutting: The excess wire, once the bristles are securely in place, is snipped away, ensuring the ferrule can fit snugly around the bristle bundle.
Step 7: Adjusting: Any misaligned or stray bristles are adjusted, and the shape is further refined.
Step 8: Measurements: The brush is measured for length, diameter, and other specifications, ensuring it meets quality standards and is consistent across the product line.
Step 9: Flattening: Brushes meant to have a flat shape undergo a flattening process.
Step 10: Dripping Glue: To securely fasten the bristles within the ferrule, a specific adhesive is dripped into the ferrule’s base after the insertion of the bristle bundle. This ensures longevity and reduces bristle fallout.
Step 11: Assemble: The brush head (bristles and ferrule) is then assembled onto the handle. Depending on the design, this could be glued or screwed in place.
Step 12: Cleaning: The final step involves cleaning the brush to remove any residue or stray bristles.
Step 1: Measurement of the badger hair
The diameter and the weight of the materials for the brush head required are initially determined through the borehole of the brush handle.
Step 2: Profiling of the shaving brush hair
The “forming block” has an internal contour that gives the brush head its shape. For this purpose the badger hair bundle is placed tip-first into the “forming block” and carefully “tapped” until the desired profile is accomplished.
Step 3: Tie thread and dripping glue
To secure the bristles, they are tightly bound using thread, which ensures they stay together and gives the brush its initial shape. In the end, dripping glue, the bundle of hairs is get glued.
Step 4: “plucking” the shaving brush
The artisan handwork of the brush maker shows in the “plucking”. The unevenness is then corrected by hand in the course of the surrounding dark design. In the brush makers lingo this is called the ”plucking”. This is how the finished shaving brush head gets its symmetrical profile with the design running consistently in parallel.
Step 5: Insert shaving brush head in handle
The last step is to insert the shaving brush head into the handle. Before this, the quality of the shaving brush head gets checked again.