Deburring & Edge Rounding – Transport & Mounting – Mechanised & Fully Automated Sheet Metal Processing – Surface Finishing KULLEN-KOTI will be showcasing solutions for all these topics at Blechexpo 2025 in Stuttgart, from October 21 to 24. Visit us in Hall 3 – Booth 3602
Multitalents in Modern Sheet Metal Processing
KULLEN-KOTI presents a wide range of brush systems at Blechexpo. Brush systems from KULLEN-KOTI have become indispensable in modern sheet metal processing. Once again, the manufacturer is using Blechexpo in Stuttgart to give visitors an insight into its current portfolio for this area of manufacturing technology. The focus will be on tool brushes for deburring and refining metallic surfaces, as well as various brush types designed for use in fully automated sheet metal processing. Of particular interest to machine builders are the company’s brush plates, which offer versatile solutions for integration into production systems.
Which brush tools are best suited for deburring metal components or for use in fully automated machining centers? Which brush systems are considered ideal for the optical or functional surface finishing of tailored blanks? And which brushes can be used for transporting and securing sheet metal panels during processing?
Answers to all these questions can be found by visitors at this year’s Blechexpo at KULLEN-KOTI’s booth 3602 in Hall 3. Once again, the renowned manufacturer showcases a wide range of exhibits to demonstrate the vast application potential of technical brushes in sheet metal processing. On display are round and cup brushes with various fill materials for deburring and derusting, twisted brushes for internal machining of bores, roller brushes for targeted or large-area surface finishing, and disc and duplex disc brushes for robot-assisted edge rounding. In addition, the company will present its brush plates, which enable the gentle and scratch-free movement of sensitive sheet metal panels during processing in laser or punching systems.
Flexible and Sustainable Deburring
Brush deburring is one of the most flexible methods in mechanical deburring technology and can be easily integrated into existing processes, especially because the required brush tools can often be mounted in existing machines. It can be used manually, with conventional machines, or in fully automated CNC production cells. Since it does not require the use of chemicals or thermal energy, it is considered a highly sustainable method.
Moreover, brush deburring is suitable for both single-part production and high-volume processing, making it an attractive solution for small batch manufacturers as well as large-scale producers and OEMs.
At Blechexpo, the specialists from KULLEN-KOTI will specifically highlight how users can significantly influence the deburring results by selecting the right brush fill material.
Typical requirements include: high material removal rates in short cycles, smoothing long profile edges, or ultra-precise edge rounding in the micrometer range — just to name a few examples.
Therefore, the material, geometry, and design of the brush fill must always be optimally matched to the specific application.
At the trade fair, the company will showcase various types of brush fills made from abrasive filaments and special wires, which give the deburring brushes either a grinding or striking effect.
Visitors will also learn that performance optimization for abrasive brushes depends on the type of abrasive material used (e.g. silicon carbide, aluminum oxide, diamond) and the grit size, while for wire brushes it depends on material hardness, wire diameter, and geometry (e.g. smooth, crimped, twisted).
Additionally, the experts will explain why brush speed and the approach and movement of the brush on the workpiece also play a crucial role in achieving the optimal configuration for a deburring brus
Optimizing Surfaces
Another key focus for KULLEN-KOTI at Blechexpo is surface treatment. The company will showcase a selection of its spiral roller brushes, disc brushes, and cylindrical brushes, which enable precise brushing, grinding, and deburring of sheet metal surfaces in automated through-feed systems.
The objectives range from enhancing product design and improving cleanability to preparing surfaces for subsequent processing steps.
Among the standard solutions for finishing steel, stainless steel, light metal, and non-ferrous sheet surfaces are spiral roller brushes from KULLEN-KOTI. These are available in various configurations — with full fill, spiral winding, or single/double band — and operate at partially high rotational speeds. They can be flexibly adapted to the specific application. Key selection criteria include not only the fill material, but also the bristle diameter and fill density.
A frequently used alternative for surface finishing of sheet metal are the company’s stamped round and roller brushes. Thanks to a wide range of options in brush body design, fill materials, and custom fill patterns, they are particularly suitable for surface-related tasks that do not require high rotational speeds or strong mechanical stress on the brush. Typical applications include oiling, matting, or cleaning of metal sheets.
Stamped round and roller brushes are lightweight and highly versatile in use.
Among the trade fair highlights from KULLEN-KOTI are once again the company’s variously configurable disc brushes. Here too, the factors of fill material, bristle diameter, and fill density play a major role in the result.
If a strong abrasive effect is required — as is often the case with roughening or deburring — the disc brushes can be equipped with polyamide bristles embedded with abrasives (e.g. silicon carbide, aluminum oxide, diamond).
If a smoothing or polishing effect is desired, the disc brushes are fitted with soft fill materials.
At the trade fair, KULLEN-KOTI will also provide information on why disc brushes are an ideal solution for use in robotic cells or other fully automated systems.
Reliable and Gentle
Using its brush plates as an example, the company will also demonstrate at Blechexpo that it is a sought-after supplier for many OEMs of manufacturing and conveying systems for sheet metal processing. As components of clamping and fixing systems in sheet metal processing equipment, these brush plates are practically a guarantee of quality. While the laser cutting or punching heads of the machine tools approach the sheet metal panels or tailored blanks from above, the brush plates ensure their precise positioning and gentle handling from below.
As standard, the company supplies its brush plates with load capacities of up to 2,000 kg/m², with formats and dimensions that can be individually customized. In addition, KULLEN-KOTI offers a wide range of fill options for these plates. Commonly used are synthetic fibers, heat-resistant and flame-retardant special fibers, or fine wires.
Even when noise reduction is a concern or particularly sensitive sheet metal surfaces need to be considered, the company’s fill portfolio offers a suitable solution.
Compared to other systems, brush plates offer a weight advantage, allowing for higher processing speeds and lower drive power requirements.