Abstract: An improved mascara brush has a typical twisted wire core containing bristles having a double lumen cross-section. The bristles are generally circular in shape, and hollow, with a dividing web across the midpoint of the bristle, thereby defining two longitudinal lumens extending along the length of the bristle. In other embodiments, the bristle is oval, square, rectangular or another polygonal shape.

Abstract: A method of manufacturing a mascara brush provides a mascara brush with bristle fibers that are split into numerous fragments. The mascara brush is made with bristle fibers having longitudinal voids. The brush is then conditioned by passing a rotating wire wheel over the bristle fibers. The wire wheel splits the bristle fibers into numerous bristle fragments. The conditioned brush is softer to the touch than the original mascara brush. The conditioning can be applied to the entire brush or one or more zones of the brush. The conditioning can be shallow, so that only the bristle tips are conditioned, or deep, so that a substantial length of the bristle is conditioned.