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.
Advanced Coatings
Modern paints are thicker, more sophisticated and more demanding than the coatings used decades ago, driving the need for advanced brush engineering.
Higher Expectations
Today's painters and consumers expect better coverage, finish quality, durability and ease of application than ever before.
Global Competition
Manufacturers must continuously innovate to differentiate their products in increasingly competitive markets and stay ahead of evolving customer expectations.
Material Evolution
Natural bristle has largely been replaced by engineered synthetic filaments, unlocking greater performance potential while increasing technical complexity and development challenges.
Continuously tapered extrusion technology
We engineer synthetic filaments that taper continuously from base to tip.
Our in-house technologies combine polymer blending, tip processing and performance testing to create fibres for demanding brush applications.
Technology Built In-House
We build most of our own equipment for extrusion, tipping, flagging, mixing and bundling—giving us tighter process control, faster development and efficient production.
Precision Tip Processing
Our self-engineered processing systems control tip shape and consistency for each application, delivering repeatable brush performance at production scale.
CONTROLLED
TIP GEOMETRY
Fibre Mixing & Bundling
Servo-controlled systems precisely manage fibre blends, colour distribution and bundle construction. Our own machine designs make consistent results economical at scale.
UNIFORM
BLENDING
Tested Performance
Our in-house 5-axis robot standardises brush application for repeatable comparisons. We measure paint delivery, finish, brush feel and durability to validate performance.
VALIDATED
PERFORMANCE DATA
Complete Fibre Systems
We deliver complete, ready-to-use fibre systems, simplifying your supply chain and reducing the need for further processing.
Build What Others Cannot
Tailored tapers, blends, tips and bundles help you create products that standard fibres cannot match.
Faster Development – Lower Risk
Extrusion, processing and testing under one roof help move ideas into production faster.
Performance You Can Prove
Measured paint delivery, finish and durability give you evidence for product development and sales.
Why Integration Matters
Driven by Change
Advanced paints and rising expectations demand more than filament production. We bring materials, processing and testing together to help brush makers keep pace.
Advanced Coatings
More demanding paint formulations need better-engineered brushes.
Higher Expectations
Painters expect better coverage, smoother finishes and longer brush life.
Global Competition
Distinctive products help brush makers compete in crowded markets.
Material Evolution
Engineered synthetics offer new possibilities—and require greater technical expertise.
Continuously tapered extrusion technology
We produce synthetic filaments that taper continuously from base to tip, using proprietary extrusion and process control.
Our technology combines polymer blending, fibre engineering and performance testing to create brush systems for demanding applications.
Technology Built In-House
We develop and build most of our own extrusion, tipping, flagging, mixing and bundling equipment. Keeping these technologies in-house gives us direct control over production, supports faster development and helps make advanced fibre systems commercially viable.
Precision Tip Processing
Tip shape influences how a brush handles and applies paint. Our self-engineered, PLC-controlled processing systems create controlled tip geometries for different application needs, combining consistent brush performance with repeatable production at scale.
CONTROLLED
TIP GEOMETRY
Fibre Mixing & Bundling
Servo-controlled mixing and bundling systems manage blend ratios, colour distribution and bundle construction with precision. Multiple fibre inputs are metered and assembled using programmed process logic, giving customers consistent fibre blends through an economical, scalable manufacturing process.
UNIFORM
BLENDING
Tested Performance
Our in-house validation platform brings robotic paint application and precision measurement together. A proprietary 5-axis robot standardises brush loading and strokes, allowing repeatable comparisons of coating build, finish, brush feel and durability across paints and surfaces.
VALIDATED
PERFORMANCE DATA
Complete Fibre Systems
We supply complete, ready-to-use fibre systems, combining extrusion and secondary processing in one platform. Customers gain a simpler supply chain, less further processing and a more direct route from fibre selection to brush production.
Build What Others Cannot
Taper profile, polymer blend, tip geometry and bundle construction work together to shape brush performance. We tailor these features to help customers develop differentiated products beyond standard fibre options.
Faster Development – Lower Risk
With extrusion, processing and testing under one roof, development decisions can be checked directly against production and application results. This helps new ideas move towards commercial manufacture with greater confidence.
Performance You Can Prove
Controlled testing measures paint delivery, finish quality and service life. The resulting evidence helps customers refine products and explain their performance advantages in sales and market positioning.
Why Integration Matters
Driven by Change
Paint formulations, application needs and customer expectations continue to change. Meeting them requires connected expertise in materials, extrusion, secondary processing and testing. Our integrated technology platform helps brush manufacturers turn these changes into practical product opportunities.
Advanced Coatings
More demanding paint formulations need better-engineered brushes.
Higher Expectations
Painters expect better coverage, smoother finishes and longer brush life.
Global Competition
Distinctive products help brush makers compete in crowded markets.
Material Evolution
Engineered synthetics offer new possibilities—and require greater technical expertise.