Abstract: A method and apparatus for making reusable paint rollers comprised of a core formed of thermoplastic material. The core is formed by helically winding one or more strips of thermoplastic material about a stationary mandril. A layer of adhesive is then applied to the outer surface of the core whereupon a cover, applied as a strip of material or as blown on fibers, is bonded thereto. The core may also be formed by applying liquefied thermoplastic material to a driven belt which transfers the thermoplastic material to the mandril. The paint roller may also be made by bonding, in a single step, the fabric cover to the wound strip wrapped about the mandril. The cover is then pressed onto the core to form a tight and secure bond therebetween.