Abstract: A roller includes an inner core assembly surrounded by a rigid expanded foam roller body, preferably having closed-cell foam with a density of 2 pcf or denser. The foam roller body may be formed by injecting or pouring expandable foam into a mold, or by spraying expandable foam over the inner core assembly, allowing it to cure, and machining it to desired specifications. The use of expanded foam cuts the costs of raw materials, production, labor, etc. To provide abrasion resistance and/or traction, a protective outer layer is provided over the foam roller body, preferably having a thickness of 0.5 inches or less, and a run-out of 0.1 inches or less. The outer layer helps make the foam roller body strong and durable enough for conveyor, pulley, and other industrial applications.