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 extrusion and secondary 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, improved finish quality and reliable large-scale production.
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. This capability supports the development of application-specific fibre combinations while ensuring consistency from prototype to production.
UNIFORM
BLENDING
Performance Validation Technology
Our in-house performance validation platform combines robotic paint application, measurement systems and real-world durability testing to quantify brush performance. A proprietary 5-axis testing robot enables bias-free comparative analysis of paint application, coating build and finish quality, while also evaluating brush feel, fatigue characteristics and service life across multiple substrates and application 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 scalable 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.
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.