As someone who spent the first two years out of college designing a full mouth electric toothbrush as the lead mechanical engineer, unfortunately making one in your garage is unlikely to go well. Bristling (or tufting as it’s known in the industry) is pretty much only done at very high volumes—minimum order quantities don’t go lower than 100,000 (or at least they didn’t back in 2010⁄11). One of the reasons our toothbrush didn’t make it to market was that there’s no established method for prototyping small quantities of tufted products because at this point they’re so commoditized. The one functional prototype we made was produced by harvesting bristle bundles from off the shelf toothbrushes and hand gluing them to the prototype using food-safe super glue. The next step was going to be dropping a couple million on custom tooling for a trial run of thousands of brushes 😭
As someone who spent the first two years out of college designing a full mouth electric toothbrush as the lead mechanical engineer, unfortunately making one in your garage is unlikely to go well. Bristling (or tufting as it’s known in the industry) is pretty much only done at very high volumes—minimum order quantities don’t go lower than 100,000 (or at least they didn’t back in 2010⁄11). One of the reasons our toothbrush didn’t make it to market was that there’s no established method for prototyping small quantities of tufted products because at this point they’re so commoditized. The one functional prototype we made was produced by harvesting bristle bundles from off the shelf toothbrushes and hand gluing them to the prototype using food-safe super glue. The next step was going to be dropping a couple million on custom tooling for a trial run of thousands of brushes 😭