Custom Polyurethane Rollers

For conveyors, material handling, mining and OEM equipment

Solid or PU-coated rollers engineered for abrasion resistance, load capacity, and long service life. Precision-machined to your drawing up to 80″ diameter, with crowned profiles for reliable belt tracking.

Request a quote for this part

Technical specifications

Material: Cast PU bonded to steel or aluminum core
Shore hardness: 60A – 95A
Sizes: Custom to drawing, up to 80″ diameter
Temperature range: -40°C to +80°C
Bonding: Chemical bond to metal core
Surface finish: Smooth, grooved, or crowned

Solid polyurethane rollers vs PU-coated cores

We build rollers two ways. A solid polyurethane roller is cast entirely in PU around a shaft or bore, well suited to lighter loads and smaller diameters where the whole rolling body benefits from the material's resilience. A PU-coated roller bonds a polyurethane band onto a steel tube or hub, combining the structural strength of the metal core with an abrasion-resistant, low-noise contact surface. The right choice depends on load, diameter, and how the roller mounts in your equipment.

Roller types we manufacture

Willsup produces the full range of conveyor and drive rollers:

Idler rollers that support and shape the belt along its run
Drive rollers that transmit torque to move the belt
Guide rollers that keep the belt or load aligned
Conveyor rollers for general belt support and transfer

Why polyurethane outperforms rubber and steel

Against steel rollers, a polyurethane surface absorbs impact at the contact point, which reduces noise and vibration transmitted through the conveyor frame. Against rubber, PU holds its shape under sustained load and resists abrasion far longer, so rollers keep their profile and deliver better belt tracking. In continuous 24/7 operations, that combination extends service life and cuts the frequency of unplanned roller changes.

Crowned profiles and machining tolerances

Rollers can be finished smooth, grooved, or crowned (a slightly larger diameter at the center) to help center and track the belt automatically. Every roller is precision-machined in-house to your drawing, with tight tolerances on diameter, concentricity, and bore fit so the part runs true in the assembly.

Industries we serve

Our rollers run in material handling, mining, aggregate processing, and OEM equipment, wherever load, abrasion, and uptime matter. For a typical application, see our material handling page. Need a load-bearing wheel instead of a roller? Explore our polyurethane wheels.

Where polyurethane rollers are used

Conveyor systems
Idler rollers
Drive rollers
Guide rollers
Feed rollers
Pinch rollers

Why source polyurethane rollers from Willsup?

Solid PU or PU-coated metal cores
In-house precision machining up to 80″ diameter
Metal-to-PU bonding under one roof
Crowned profiles for reliable belt tracking
Roller recovering service available
Lower noise and vibration than steel rollers

Questions about polyurethane rollers

Can you recover existing roller cores?

Yes. We strip the old material, inspect the core, and re-cover it with the polyurethane formulation that best fits your application. This saves the cost of new cores.
What surface finishes are available?

Smooth, grooved, crowned, or custom profiles. The right finish depends on your application: grip, tracking, material release, or a combination.
What is the maximum roller diameter you can produce?

We machine rollers up to 80 inches in diameter in our machining shop. For larger sizes, contact us to discuss your requirements.
Should I choose a solid PU roller or a PU-coated core?

It depends on load and size. Solid polyurethane rollers suit lighter loads and smaller diameters, where the whole body benefits from PU resilience. PU-coated rollers bond a polyurethane band to a steel or aluminum core for higher load capacity and larger diameters. We help you choose based on load, speed, and how the roller mounts.

Ready to spec your part?

Tell us your load, size, and operating conditions and we will recommend the right formulation.