A marine robotics developer approached Brushcustom for a replacement roller brush for a hull-cleaning robot project. The customer requested a segmented construction, with individual brush sections forming the roller, and initially asked for a 10-tooth segment-body design.
That configuration would require new tooling for the small sample order. Brushcustom proposed 12-tooth zig-zag roller brush segments using a mold already available at the factory. The customer reviewed photographs of the sample body and confirmed the alternative before production. Brushcustom manufactured and shipped 70 segments at the original quotation and also supplied a CAD drawing for the customer’s development work.
Starting with an Existing Brush Specification
The initial inquiry asked whether Brushcustom could provide a similar product and a quotation. It specified 0.20 mm PA6 filament, a finished brush outside diameter of 110 mm, a core-tube outside diameter of 57 mm, and an overall length of 1,000 mm.
These figures described the brush referenced in the initial inquiry. The subsequent discussion established a different segment-body configuration, so the original roller dimensions and the selected body dimensions are recorded separately in this case.
Why This Construction Is Called Zig-Zag Segments
Zig-zag roller brushes use individual brush segments with toothed end profiles that interlock with adjacent segments. A series of these sections forms the roller brush. The zig-zag description refers to the segment-end geometry, rather than a requirement for the bristles themselves to follow a zig-zag pattern.
In this project, the customer specifically requested the segmented format. The proposed bodies had a central bore and a 12-tooth end profile. Reviewing that profile was part of agreeing on the alternative construction; a tooth count alone would not establish compatibility with the customer’s original brush.
Moving from 10 Teeth to an Existing 12-Tooth Mold
The initial 10-tooth request introduced a tooling decision. Producing that configuration would involve a new mold and a tooling charge for the small order.
The factory already had a mold for a 12-tooth zig-zag segment body. Brushcustom offered this design as an alternative and sent the customer two photographs of the sample body: an end view showing the bore and teeth, and a side view showing the body and its toothed ends.
The customer confirmed the proposed option before production began. Using the existing mold allowed the sample order to proceed with the original quotation unchanged, without making a new mold for the initially requested 10-tooth design.
Confirmed Zig-Zag Segment-Body Dimensions
The selected zig-zag segment body had a 30 mm center bore and a 54 mm outside diameter. Each segment was described as 100 mm nominal length, with an overall length of 105 mm including the end teeth. The specified tooth height was 5 mm.
| Item | Confirmed specification |
|---|---|
| Construction | Zig-zag roller brush segments |
| End-tooth configuration | 12 teeth |
| Center bore | 30 mm |
| Brush-body outside diameter | 54 mm |
| Nominal section length | 100 mm |
| Overall section length, including end teeth | 105 mm |
| End-tooth height | 5 mm |
| Quantity shipped | 70 zig-zag brush segments |
The CAD drawing supplied for the project shows the body dimensions and end-tooth detail, including the 30-degree tooth spacing. The 54 mm diameter refers to the body beneath the bristles. The 105 mm dimension is the overall length of one segment body including its end teeth; it is not the length of an assembled roller.
Manufacturing and Shipping 70 Zig-Zag Brush Segments
Following the customer’s confirmation, Brushcustom manufactured the filled zig-zag brush segments and packed them for shipment. The completed sample order contained 70 segments.
Samples and Drawing Support for Product Development
The customer is now in the product-development stage. Alongside the manufactured zig-zag segments, Brushcustom supplied a CAD drawing of the 12-tooth body. The samples and drawing give the customer’s engineering team a physical component and a dimensional reference for its development work.
The confirmed outcome is an agreed alternative design, 70 manufactured and shipped segments, and CAD drawing support, with the original quotation maintained. Operating results from the customer’s equipment are not yet included in this case.
Discuss a Zig-Zag Brush Segment for Your Robot
For a similar cleaning robot brush project, share the existing brush drawing or sample, the finished brush diameter, filament specification, bore and mounting details, segment-end geometry, required roller length, operating conditions, and sample quantity.
Brushcustom can review these requirements for custom zig-zag roller brush segments and assess whether an available body design can support the application or whether new tooling is needed.