Updated on Jun 11, 2024 3:27 AM EDT
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The best polyurethane provides a durable, smooth finish that comes in several formulas, including oil-based, water-based, and water-based and oil modified. It’s typically used to seal wood products, protecting them from moisture, dirt, and damage. Like paint, polyurethane is applied to the material’s flat surface with a brush.
The best brush for applying polyurethane differs depending on the intended application. Most smaller projects benefit from a narrow brush, while larger projects can be completed with a wider brush.
We like the Wooster Brush 5221 2½-In. Silver Tip Angle Sash Brush because of its angled synthetic and polyester brush fibers, ergonomic wood handle, stainless steel ferrule, and compatibility with water- and oil-based paints. However, all our chosen products are effective and reliable.
Read on to learn about the factors to consider as you shop, and then explore some of the top choices for the best brush for polyurethane application.
We researched the most sought-after brushes for polyurethane in their respective categories and discovered that the best options are determined by their bristles, design, width, compatibility with multiple paints and sealants, and other special features included by top brands.
While searching for the best paint brushes for polyurethane applications, we found that the most popular types of brushes among users were the synthetic, natural, and foam options for their versatility and ease of use while applying paint and water- and oil-based polyurethane. The brushes listed above vary from angled (tapered) to flat designs with 1- to 4-inch widths to take care of different application types and projects, whether applying thin coats or thick coverage.
As for durability, these painting tools are made with stainless steel, brushed-steel, copper, and plastic ferrules that hold in the bristles to prevent shedding. Wooden and plastic handles make these picks lightweight and maneuverable while in use. Plus, some of our top picks provide a smooth finish with paints and sealants like lacquer, varnish, and enamel.
Here’s a look at some of the top products on the market so users can find the best way to apply polyurethane. This list includes all three main options—natural bristle, synthetic bristle, and foam—to help users find the best brush for polyurethane application.
This high-quality brush from Wooster is an excellent option for applying a smooth finish of polyurethane to average-size woodworking projects or furniture due to its angled 2.5-inch width that’s suitable for both broad and precision strokes. The angled bristles allow the user to direct the brush tip into corners to ensure that the entire surface is evenly coated.
The brush features a smooth wooden handle that fits comfortably in most average user’s hands, providing balanced control over each stroke. Synthetic bristles made of polyester filaments achieve a smooth, soft finish with featherlight strokes making it an ideal brush for staining wood or applying polyurethane. The stainless steel ferrule is resistant to rust and corrosion, helping to ensure that the bristles remain secure through multiple uses.
Get the Wooster 5221 brush for polyurethane at Amazon, The Home Depot, or Walmart.
Choose from among five different brushes for polyurethane application in these cheap brushes from Pro Grade. The pack includes a 1-inch flat brush ideal for narrow pieces and small corners as well as a 1.5-inch angled brush suitable for crisp, clean corners and angles. Choose the 2-inch angled brush, 2-inch flat brush, or 2.5-inch angled brush for broad strokes on standard woodworking projects, like a stool or coffee table.
These synthetic-bristle brushes also can be used as brushes for staining wood, if needed. They feature a stainless steel ferrule that resists rust and corrosion while tightly holding the polyester filament bristles. Each brush also has a smooth and contoured wood handle for a comfortable grip.
What our tester says: Glenda Taylor, a Bob Vila staff writer and product tester, notes in The Best Paint Brushes for Trim that “each Pro Grade trim paint brush performed well in our tests. While their bristle tips are less refined than some of the other brushes we tested, they gave us excellent finish results when used with high-quality, self-smoothing paint. We checked the finished trim boards under strong light when they dried and saw very few brushstrokes. We were impressed overall, especially considering the set’s affordability.”
Get the Pro Grade brush set for polyurethane at Amazon.
The natural bristles on this brush from Purdy are made by blending ox hair with a white China bristle for added resilience and a smoother finish of oil-based polyurethane. A strong, durable stainless steel ferrule helps to ensure the brush doesn’t lose any bristles while in use. The angled bristles are 1.5 inches wide, allowing the user to provide a smooth finish to corners and difficult angles without issue.
Use this brush to apply a variety of oil-based coatings or sealants, including paint, enamel, varnish, polyurethane, and lacquer. It boasts a slim hardwood handle with a hanging hole for easy organization and storage that won’t damage the bristles. The brush is also available with flat bristles and in 2-inch, 2.5-inch, and 3-inch widths.
Get the Purdy Ox-O-Angular brush for polyurethane at Amazon.
The synthetic bristles on this brush from Purdy soak up water-based polyurethane, providing a soft, even finish. The smooth hardwood handle is easy to hold and control for precise brushstrokes. The brush also features a brushed copper ferrule with superior rust and corrosion resistance, helping to ensure that the bristles don’t fall out after extended use.
Use this polyester and nylon brush for touch-ups on trim or small- to average-size woodworking projects, including window shutters and door molding. The 2-inch width is suitable for long, broad strokes, and the angled bristles reach narrow corners and tight angles, providing full coverage to the entire project.
What our tester says: Glenda Taylor, a Bob Vila staff writer and product tester, notes in our tested guide that “the Purdy XL Glide’s ultrafine bristle tips left our trim boards smooth and sleek. A slight contour in the handle made it easy to hold and control the brush, and the wood absorbs light moisture to keep the handle from feeling slick should it get wet. We soaked the brush in water for a few hours before washing it out under a running faucet, and nearly all the residual paint came out.”
Get the Purdy Glide brush for polyurethane at Amazon or Lowe’s.
Don’t fight with fragile bristles that can bend, break, or fall out when this Wooster foam paint brush is a great alternative for applying polyurethane to smaller wood surfaces like a mailbox or a bird feeder, or it can be an ideal brush for wood stain on chair legs. This foam brush for polyurethane soaks up water- and oil-based polyurethane and measures 1.5 inches in width for a smooth, controlled application over a small surface. Its angled tip helps with reaching inside corners and edges.
Like some foam brushes for polyurethane, this brush has a plastic handle that is a part of its hard plastic ferrule. It has a rigid core to keep the handle and ferrule stiff, while the foam flexes and bends to achieve the best application results. The low price and moderate reusability of this brush make it an excellent option for the casual DIYer.
Get the Wooster 3103 brush for polyurethane at Amazon or The Home Depot.
Brushes smaller than 4 inches wide are great for small to average-size woodworking projects, but they lack the ability of more coverage per stroke. The girth of this 4-inch brush from Wooster Brush can quickly apply a coat of polyurethane to a table, a door, or even a feature wall. The brush features synthetic bristles made of nylon and polyester for a fine finish with both oil- and latex-based polyurethane.
The flat bristles glide polyurethane in broad strokes over the material, making it easier to apply the polyurethane in even layers. This produces a soft finish with a balanced color palette instead of splotchy, uneven coats. A solid plastic handle and a brass-plated steel ferrule help secure the bristles and maintain the high durability of the brush.
Get the Wooster Softip brush for polyurethane at Amazon or The Home Depot.
When selecting a brush to apply the polyurethane, consider the size, shape, and design, including the type of bristles, the handle, and the ferrule. Don’t forget to factor in the type of polyurethane and its intended use to achieve the best coverage and finish. Here are several details to keep in mind when choosing the best brush for polyurethane application.
Brushes can be made with natural or synthetic bristles. Some forgo the bristles entirely, opting for an angled foam material to spread the polyurethane. The best option for the project depends on the polyurethane base, the size of the project, and the shape of the material.
The brush size you choose should be based on the size of the project or the intended purpose of the brush. Common brush widths are 1 inch, 1.5 inches, 2 inches, 2.5 inches, 3 inches, 3.5 inches, and 4 inches. Brushes that are 2 inches or smaller in width are ideal for applying polyurethane in tight corners or at awkward angles with controlled precision.
Choose a 2- to 3-inch brush for most woodworking projects. These brush widths provide good coverage but can still reach into some smaller spaces. Larger projects, like finishing a table or bed frame, can benefit from a 4-inch brush that quickly covers a lot of surface area.
The ferrule of a brush is the metal part that connects the bristles to the handle. The metal needs to be strong and stable; otherwise, the bristles can bend, break, and detach from the brush. They can become stuck in the can of polyurethane or on the project, leaving an impression in the applied polyurethane that users then need to touch up.
The ferrule is typically made of aluminum or steel intended to support the bristles and keep them together. The high durability and corrosion resistance of both metals help ensure that the brush and bristles last for more than one use before needing to be replaced.
To maneuver, angle, and direct the brush, you need to grip the handle securely. It’s not impossible to apply polyurethane without a sturdy handle, but it also isn’t easy. For these reasons, don’t ignore handle design when choosing the best brush for polyurethane.
Bristle brushes usually have smooth, flat wooden handles that are easy to grip to accommodate both full strokes and small, precise strokes. Foam brushes may have a narrow wood, plastic, or metal handle extending from the ferrule like a cylindrical rod or stick. This small diameter is more suited for precise brushstrokes than broad application.
Polyurethane-based sealants and finishes are available in either oil-based or water-based options, depending on the desired appearance.
Before deciding on the best brush for polyurethane application, consider how and where you’ll use it. Bristle brushes with lower widths and foam brushes are ideal for smaller projects, while larger brushes are better for smooth, broad strokes. If applying polyurethane to a high-traffic object, like a dresser or a closet door, it’s important to use at least four coats of water-based polyurethane or at least three coats of oil-based polyurethane.
Decorative objects purely for display that often sit for weeks or months without being touched only need two to three coats of water-based polyurethane or one to two coats of oil-based polyurethane. Regardless of the material, wait 2 to 3 hours between applying additional coats.
Achieve a smooth, clean finish on your next woodworking project by choosing the most appropriate brush for applying polyurethane. If you still aren’t certain about which bristles are best suited for polyurethane or if a foam brush is a good idea, keep reading for answers to these and several more frequently asked questions about the best brush for polyurethane application.
Nylon and polyester are commonly used to make synthetic bristles. While these materials aren’t suitable for oil-based polyurethane, they are a good option for applying water-based polyurethane.
Yes, it is OK to use a foam brush to apply polyurethane. However, it isn’t the best choice for larger projects because the foam doesn’t spread the polyurethane as well as a synthetic or natural brush. Use a foam brush to apply polyurethane to smaller projects, like finishing a birdhouse.
For the best results, choose a natural-bristle brush with a durable ferrule and tightly packed bristles to apply oil-based polyurethane.
Before using any polyurethane, sand down the material with 220-grit sandpaper to achieve the smoothest possible surface. Then, wipe down the material, removing all dust particles with a clean cloth. Spread the polyurethane, allowing each coat to dry for between 2 and 4 hours before applying the next coat. Use sandpaper again to gently remove brush marks from the material’s surface, and consider applying a wood polish for a near-flawless appearance.
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