Sampling Brush Assembly Machine

Machine Overview

The Sampling Brush Assembly Machine is designed for the automatic production and assembly of both cosmetic and medical sampling brushes. It can be used for conventional eyelash and mascara brushes, as well as medical brushes such as:

• HPV sampling brushes
• Cervical cell collection brushes
• Cervical cytology brushes
• Gynecological sampling brushes
• Other disposable medical sampling brushes

The complete production line consists of two main machines:

1. Brush Head Making Machine
2. Brush Head and Handle Assembly Machine

Together, these machines complete brush-head forming and the final insertion of the brush head into the plastic handle.

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1. Brush Head Making Machine

The brush head manufacturing process requires precise control because several quality problems may occur during production, including:

• Loose or flying fibers
• Insufficient twisting of the metal wire
• Uneven bristle length
• Irregular brush-head shape
• Unstable brush-head dimensions

Our brush head making machine has undergone several generations of technical upgrades. The latest design provides improved control of fiber feeding, wire twisting, bristle trimming, and brush-head forming.

This helps ensure:

• Firmly twisted stainless-steel wire
• Uniform bristle distribution
• Consistent bristle length
• Stable brush-head shape
• Reduced loose fibers and flying lint
• Consistent quality during continuous production

For medical sampling brushes, controlling loose fibers is especially important because the brush head must remain clean, stable, and reliable during specimen collection.

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2. Brush Head and Handle Assembly Machine

The second machine automatically inserts the completed brush head into the plastic handle.

A major challenge in this process is ensuring that the twisted-wire end enters the handle smoothly and remains firmly fixed. Direct insertion may result in:

• Difficult insertion
• Handle deformation
• Incomplete assembly
• Unstable insertion depth
• Brush heads becoming loose or difficult to remove from the tooling

To solve this problem, the machine uses a controlled flame-heating process to heat and slightly melt the insertion end of the brush head before assembly.

This process helps:

• Facilitate smooth insertion into the handle
• Reduce insertion resistance
• Prevent damage to the plastic handle
• Maintain a consistent insertion depth
• Improve the connection strength between the brush head and handle
• Reduce assembly defects

The heating temperature, processing time, insertion depth, and assembly position can be adjusted according to the customer’s brush design and material.

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Main Technical Specifications

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Main Advantages

High-Speed Automatic Production

With an output of approximately 50–60 pieces per minute, the production line is suitable for large-scale manufacturing of cosmetic and medical sampling brushes.

Stable Brush-Head Quality

Precise fiber feeding, wire twisting, trimming, and forming help produce brush heads with uniform dimensions and consistent performance.

Reduced Fiber Contamination

The machine design helps reduce loose fibers and flying lint, making it more suitable for medical sampling-brush production.

Reliable Brush-to-Handle Assembly

Controlled heating and insertion improve assembly stability and reduce problems associated with difficult or incomplete insertion.

User-Friendly Control

The Panasonic PLC provides stable automatic control of the machine sequence, operating parameters, and production process.

Reliable Pneumatic Components

The machine uses AirTAC pneumatic components to ensure stable movement, accurate positioning, and convenient maintenance.

Flexible Product Compatibility

The tooling and process parameters can be customized for different:

• Brush-head shapes
• Bristle materials
• Wire diameters
• Handle dimensions
• Insertion depths
• Production speeds
• Medical or cosmetic applications

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Customized Machine Solutions

The machine can be customized according to the customer’s product samples and technical requirements, including:

• Brush type and dimensions
• Fiber material and bristle length
• Metal-wire diameter
• Brush-head shape
• Handle material and structure
• Heating method
• Insertion depth
• Production capacity
• Vision inspection
• Automatic rejection
• Product counting and collection
• Cleanliness and enclosure requirements

Hotlink provides complete customized solutions covering process evaluation, machine design, manufacturing, assembly, testing, commissioning, and after-sales service.