Abstract: A method for making a brush element for a brush roller wherein bristle bunches formed by folding bristles over bent portions of U-shaped staples have their folded portions and associated staples inserted through tight fitting apertures in a base portion of a frame so that legs of the staples are bent by collision with a facing side of an attachment section of the frame. A hardenable adhesive is then poured into the frame between the base portion and the facing side around the staples and folded portions of the bristle bunches. The adhesive is hardened, bonding the staples in the adhesive and affixing the bristles to the base portion. The adhesive may be a polyurethane-base resin having viscosity allowing absorption of the adhesive between the bristles near their folded portions, the tight fit of the bristles in the apertures holding them in place during pouring and hardening of the adhesive.