Based on application of reactive multiple-part urethanes directly onto rotating roll core, rotary casting eliminates need for poured molds and secondary curing process. Process creates solid roll cover within minutes, and rolls can be delivered in days. Hardness and uniformity are held consistently across roll to within +3 ShA points or better for optimal mechanical properties. Roll sizes can be produced from 6–71 in. dia and up to 472 in. long.