Continuously tapered extrusion technology
We are one of the few manufacturers globally capable of producing continuously tapered synthetic filaments. Using proprietary extrusion and process control technologies, filament diameter is gradually reduced from base to tip in a single continuous manufacturing process.
Beyond continuous taper, Nexstar’s technology platform includes advanced polymer blending, fibre dyeing, cross-sectional engineering, surface modification and in-house performance validation.
Engineering Our Own Technology
Nexstar develops and builds most of its own processing equipment, including systems for extrusion, tipping, flagging, mixing and bundling. This enables greater process control, faster innovation and a cost-efficient manufacturing platform.
Tip Processing Technology
Nexstar develops and operates advanced tip processing technologies designed to create controlled filament tip geometries for specific application requirements. Precise control over tip shape and consistency enables repeatable brush performance, and reliable large-scale production. Our journey has evolved from Robinson-era systems of the 1940s to self-engineered, PLC logic-controlled processing platforms. We support reliable large-scale manufacturing without compromising the application characteristics required for each product type.
CONTROLLED
TIP GEOMETRY
Fibre Mixing & Bundling Technology
Our servo controlled fibre mixing and bundling systems enable precise control over filament composition, blend ratios, colour distribution and bundle construction. Proprietary machine design, servo motion control and programmed process logic allow multiple fibre inputs to be metered, combined and assembled with high repeatability. The systems are designed for economical and scalable production, giving our customers access to highly controlled, repeatable fibre constructions without dependence on conventional high-cost processing platforms.
UNIFORM
BLENDING
Performance Validation Technology
Our self-developed performance validation platform integrates robotic paint application, precision measurement systems and controlled durability testing within a single in-house evaluation environment. At its core, a proprietary 5-axis testing robot standardises brush movement, loading, stroke geometry and test conditions to enable bias-free, repeatable comparative analysis. Integrated measurement and test protocols allow Nexstar to systematically quantify coating build, finish, brush feel, fatigue behaviour and service life across multiple substrates, paint systems and operating conditions.
VALIDATED
PERFORMANCE DATA
Complete Fibre Systems
Nexstar focuses on delivering complete, ready-to-use fibre systems rather than partially finished filaments. This integrated capability is unique among continuously tapered filament manufacturers and gives customers a simpler, faster, more economical and more reliable supply chain.
Build What Others Cannot
From taper profile to polymer blend, cross-section, tip geometry and bundle construction, Nexstar can engineer filament systems that are difficult for standard suppliers to replicate.
Faster Development – Lower Risk
Because extrusion, secondary processing and validation sit under one roof, new ideas move quickly from concept to production, shortening development time and accelerating commercialisation.
Performance You Can Prove
Brush feel, paint delivery, finish quality and service life are measured through controlled in-house testing, giving customers evidence they can use in product development, sales and brand positioning.
Need for Integrated Technology
Driven by Change
Paintbrushes are no longer what they were decades ago. Paints are more advanced, application needs have changed, competition has intensified and customer expectations continue to rise. Meeting these challenges requires more than filament production alone. It demands expertise across materials, extrusion, secondary processing and performance validation. This is why Nexstar continues to invest in a broad technology platform designed to support the evolving needs of the global paintbrush industry.