Durable transfer roll core and method of making and using the same

1. A method of grooving a durable transfer roll core, comprising: loading the durable transfer roll core onto a grooving apparatus; and pulling the durable transfer roll core through the tooling section of the grooving apparatus such that a main surface of the durable transfer roll core is grooved via engagement with one or a plurality of cutting tools of the tooling section of the grooving apparatus further comprising the step of running a cable, rope, or chain through the tooling section and through the durable transfer roll core to pull the durable transfer roll core through the tooling section.

2. The method of claim 1 , wherein the cutting tools are selected from the group consisting of a bit, a blade, a rotating tool bit, a knurling tool, a melting tool, a reciprocating or banded saw blade, a rotary saw, a laser, and combinations thereof.

3. The method of claim 1 , wherein the cutting tools are placed at different positions around the tooling section.

4. The method of claim 1 , wherein the cutting tools surround multiple points around the durable transfer roll core as the durable transfer roll core travels through the tooling section.

5. The method of claim 1 , further comprising the step of rotating the durable transfer roll core as it travels through the tooling section.

6. The method of claim 1 , further comprising the step of forming ridges disposed at the main surface of the durable transfer roll core.

7. The method of claim 1 , wherein at least one cutting tool engages the main surface and wherein at least one cutting tool does not engage the main surface of the durable transfer roll core.

8. The method of claim 1 , wherein a spiral groove pattern is formed into the main surface of the durable transfer roll core.

9. The method of claim 1 , further comprising the step of unloading the durable transfer roll core form the grooving apparatus.

10. The method of claim 1 , wherein the durable transfer roll core rotates as it is pushed or pulled.

11. The method of claim 1 , further comprising attaching the cable, rope, or chain to a pulling base that rests against an end edge of the durable transfer roll core.

12. The method of claim 1 , wherein loading the durable transfer roll core onto the grooving apparatus comprises positioning the durable transfer roll core on a loading support section of the grooving apparatus.

13. A method of grooving a durable transfer roll core, comprising: surrounding the durable transfer roll core with a grooving apparatus; and moving the grooving apparatus around and/or along the durable transfer roll core via a cable, rope, or chain through the tooling section and through the durable transfer roll core to pull the durable transfer roll core through the tooling section such that a main surface of the durable transfer roll core is grooved via engagement with one or a plurality of cutting tools of the tooling section of the grooving apparatus; and moving a second grooving apparatus around and/or along the durable transfer roll core such that a main surface of the durable transfer roll core is grooved via engagement with one or a plurality of cutting tools of a second tooling section of the second grooving apparatus.

14. The method of claim 13 , wherein the durable transfer roll core rotates as the grooving apparatus moves around or along the durable transfer roll core.

15. The method of claim 13 , wherein the grooving apparatus rotates around the durable transfer roll core.

16. The method of claim 13 , wherein the grooving apparatus moves along the longitudinal axis of the durable transfer roll core.

17. The method of claim 13 , wherein the grooving apparatus rotates around and moves along the axis of the durable transfer roll core.