As a core component of daily cleaning tools, household cleaning brushes require a manufacturing process that balances durability, cleaning efficiency, and safety. The complete manufacturing process can be divided into four steps: raw material preparation, injection molding, bristle implantation, and assembly and inspection.
During the raw material preparation stage, high-density polypropylene (PP) or nylon (PA6.6) is preferred as the bristle base material, as both materials offer both wear resistance and flexibility. The handle is typically made of ABS plastic, with the moisture content of the raw material controlled to below 0.3% in a dryer to prevent air bubbles during injection molding.
During the injection molding process, a precision injection molding machine melts the plastic pellets at a temperature of 180-220°C, and a hot runner mold rapidly forms the handle structure. The mold temperature must be precisely maintained at around 60°C to ensure a smooth, flash-free surface. Special handles with slots require additional ribs to enhance deformation resistance.
The core technology is bristle implantation. An automated implanting machine inserts nylon filaments into the grooves of the injection-molded brush head at intervals of 0.5-1.2mm. Modern production lines commonly utilize ultrasonic welding, which uses high-frequency vibrations to form a molecular bond between the filaments and the plastic matrix, resulting in a strength that is over three times stronger than traditional gluing. The density of the bristles varies depending on the intended use. For example, a tile cleaning brush may have 120-150 bristles per square centimeter.
The final inspection stage undergoes five levels of quality control: bristle hardness testing (45-60 Shore A hardness), salt spray corrosion resistance testing (48-hour rust-free), handle load-bearing testing (≥5kg pull), and microbial residue testing. Qualified products are packaged in moisture-proof PE bags and labeled in accordance with the GB/T 38262-2019 "General Technical Requirements for Cleaning Appliances."
Through modular design and the application of automated equipment, this process shortens the production cycle of a single brush to 45 seconds, and the yield rate is stabilized at above 98.6%, which not only meets household cleaning needs but also complies with environmental protection and safety standards.