Abstract: Methods and apparatus for automated brush assembly are disclosed. A method of end-rounding bristle ends with an abrasive surface in random orbital motion relative to bristle tufts held in a movable gripper is described. A novel tuft carrier adapted to hold a plurality of bristle tufts in an arrangement suitable for direct mechanical insertion into the tuft chambers of a brush mold is also described. The tuft carrier has a plurality of tuft insertion cavities and a plurality of movable clamps, each clamp adapted to at least partially occlude one of the cavities when closed. Individual bristle tufts, having a fused end and a rounded or non-rounded bristle end, are transferred from a movable gripper to the tuft carrier by direct mechanical insertion. In addition, an apparatus for direct mechanical insertion of bristle tufts from a tuft carrier into the tuft chambers of a brush mold is described.