03-24-2017, 09:39 AM
#1
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Hey all-

A few months back I got it in my head that I'd like to design and make a brush.  Over the next couple of posts, I'll share the process and steps I went through to bring this project together.  Given how much we like pictures, there will be more pictures than words...but if you want some more detail, or have some questions, please ask!

Here's a teaser photo...

[Image: U04MPiZ.jpg]

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 03-24-2017, 09:48 AM
#2
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Some initial ideas on paper.  A few sketches of the brush and handle...

[Image: Sbmc2Te.jpg]

[Image: r7AE3AF.jpg]

[Image: 5eB8gMP.jpg]

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 03-24-2017, 09:53 AM
#3
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Comparing the initial sketches to brushes I own and use on a regular basis.  Trying to get a sense of scale, fit in the hand, and general ergonomics through the comparison...there are a couple of different sketches being used, each slightly different in terms of dimensions.

[Image: D6MJEOZ.jpg]

[Image: kJwyN1S.jpg]

[Image: SRHabdR.jpg]

[Image: 8ZJJwyT.jpg]

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 03-24-2017, 10:18 AM
#4
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Tom, this will be a great thread to follow.  Thanks for sharing this process with us.

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 03-24-2017, 01:17 PM
#5
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Thanks Ricardo!

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 03-24-2017, 01:21 PM
#6
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With a good sense of the shape of the handle and the general size, I built a 3D model to refine my ideas...

[Image: XOH1SEf.png]

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[Image: Yl8FQaW.png]

Once the model was built, the possibilities for manipulating it and testing different ideas was endless...and relatively simple.  Almost too simple, as the variations, mostly subtle, grew dramatically.

[Image: tp9L6Xg.png]

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 03-24-2017, 05:18 PM
#7
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I settled on a design that I felt would work best in my hand.  Going into it, I planned on using a 24mm knot and the design was built around accommodating that...or so I thought...

[Image: OWbuCbj.png]

My original intent was to have a wood handle, with a faux ivory or black accent ring right at the base of the knot.  My interest in doing this project, and making it out of wood, was inspired by the work a friend did for me on an espresso machine restoration I finished last year.  I asked him to replicate the OEM bakelite handles for the machine out of African Blackwood (the wood clarinets are made from).  They came out beautifully and matched the original handles exactly.  When they arrived and I installed them I thought...I bet he can turn a brush handle for me!  

[Image: hkl28la.jpg]

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I wanted to send my friend something other than drawings to explain the design. 3D printing, which I've been wanting to explore, came to mind.  Not only could I print the design to test the feel in the hand and the fit of the knot, but I could also have a working prototype by setting the knot with silicone.  The final design could then be sent to my friend to copy.

The first prints...

[Image: 3ZOIFUF.jpg]

[Image: ojXGFFM.jpg]

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 03-24-2017, 06:39 PM
#8
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amazing!

i was thinking about working with an artisan to produce a my very own brush.  you know, just the way i like it.  now you have inspired me.  it is a most!

thanx tons

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 03-25-2017, 02:43 AM
#9
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Fun thread to follow. Thanks for sharing the process! The design looks great!


Sent from my iPhone using Tapatalk

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 03-25-2017, 03:24 AM
#10
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Thanks for posting this thread.  It certainly opens a large number of possibilities.

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 03-25-2017, 03:54 AM
#11
  • Rufus
  • Senior Member
  • Greater Toronto Area
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Intriguing and an enjoyable thread.   How solid are the 3-D printed handles?  Are they solid enough to be used on a daily basis?

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 03-25-2017, 06:53 AM
#12
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Great approach!  (I love it.)  As you've found out, designing a good handle--tweaking the design, and testing the results in the real world to get it exactly right--involves a lot of work.  Well done!

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 03-25-2017, 07:11 AM
#13
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What a great thread....cant wait to see more.

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 03-25-2017, 07:35 AM
#14
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Thanks gentlemen!  @Rufus, yes the prints are solid enough to use.  They are printed from a biodegradable plastic (PLA) from what I understand, but hold up to regular use and water exposure.  For how long, I don't know but they seem pretty durable.  There are a variety of more expensive materials, and ones that don't degrade either, like ABS and acrylic I think.  I am no expert so open to others correcting me on this!

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 03-25-2017, 07:40 AM
#15
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Testing the feel in the hand...

[Image: LMZKTC1.jpg]

[Image: Bz5AxHa.jpg]

...and with a ratty Parker knot just for scale...

[Image: nV0N2vu.jpg]

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 03-25-2017, 07:44 AM
#16
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While I liked the feel of the handle, I decided I wanted something more substantial...bigger handle, bigger knot...maybe like a Chubby (which I don't own).  So I went back to the 3D model and scaled the original up several different levels (5%, 10%, 20%) and adjusted the socket for the knot...

[Image: hY54lpH.jpg]

and ended up with this pile of prints...

[Image: d91pgm9.jpg]

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 03-25-2017, 08:41 AM
#17
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A very interesting thread... out of curiosity, roughly how long do each print take?

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 03-25-2017, 09:14 AM
#18
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Honestly not sure. I think 3+ hours. More if it's higher resolution. I send it to a printer close to my office. He runs them overnight and I pick up next day. He runs 12 printers so if I have 2 or 3 items to print he runs them concurrently.

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 03-25-2017, 09:49 AM
#19
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Thanks - I've been kinda wanting a 3D printer and that guestimate is a good indicator of what I might have patience to try on one.

Looking forward to seeing more of your brush Smile

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 03-25-2017, 12:48 PM
#20
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As you can see, I did quite a few prints with different dimensions.  My original version and the scaled version were intended for 24mm, 26mm and 28mm knots.  I test fit a few knots and quickly realized that I really needed to allow more room for the knot so I could set it at the right height.  I finally settled on a 26mm knot with a 28mm socket.  This meant I had to rework the profile of the handle so it was wider at the top and could accommodate the wider socket.  Here are a couple of prototypes with a 24mm and 26mm knot...neither worked that well, the knots were too cramped...

[Image: ctLD5uf.jpg]

Here is the final model I ended up with after fiddling with the dimensions, a few reprints, and testing with the 26mm knot...

[Image: tAPPe71.jpg]


[Image: pFcd5fs.jpg]

[Image: YyohZjP.jpg]

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