Processes for manufacturing personal-care applicator

A process for manufacturing a personal-care applicator, the process comprising:

• providing at least a first elongated stem having a proximal end and a distal end, wherein the first elongated stem has an angled cut proximate the distal end;
• manufacturing at least a first bristled component comprising:
• an elongated carrier having a longitudinal axis and a length, wherein the carrier has at least one longitudinal slot disposed along at least a portion of the length of the carrier, and
• at least a first plurality of bristles ultrasonically welded directly to the carrier and outwardly extending therefrom according to a first pre-determined pattern, wherein the carrier and the bristles comprise ultrasonically compatible materials, and wherein the bristles are ultrasonically bonded to the carrier through a direct ultrasonic bond between at least one interior surface of the at least one longitudinal slot of the carrier and a lengthwise portion of each of the bristles;
• wherein manufacturing the at least first bristled component comprises:
• continuously wrapping at least a first strand of material around a continuously moving endless band having a top side, a backside, and at least a first edge therebetween, thereby causing the at least first strand of material to come into contact with the at least first edge of the band at a predetermined density;
• continuously juxtaposing at least a first support strip with the first edge of the band having the first strand of material wrapped around the first edge, the first strand of material and the first support strip comprising ultrasonically compatible materials;
• ultrasonically welding lengthwise portions of the first strand of material adjacent to the first edge to the first support strip at the predetermined density and such that said lengthwise portions of the first strand of material become ultrasonically bonded to the first support strip through a direct ultrasonic bond between a surface of the first support strip and surfaces of said lengthwise portions of the first strand of material, thereby forming at least a first continuous bristled strip comprising the first support strip and a plurality of first-strand filaments ultrasonically welded to the first strip and outwardly extending therefrom;
• removing the at least first continuous bristled strip from the endless band;
• cutting the at least first continuous bristled strip into a plurality of bristled components;
• and
• modifying at least one physical characteristic of the first strand of material;
• attaching the at least first bristled component to the at least first stem, such that the carrier extends from the distal end of the stem;
• and
• cutting the stem to provide an angle to the personal-care applicator proximate the distal end.